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CROSS REFERENCE TO RELATED APPLICATION
This application is related to an application filed concurrently herewith, entitled “Tapered Slot Feed for an Automotive Radar Antenna,” U.S. application. Ser. No. 10/978,779, now pending which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to an antenna structure having a patch array antenna feed in conjunction with a parabolic dish, particularly useful in a collision detection system in a vehicle.
BACKGROUND
Automotive technologies continually strive to make vehicles safer. In one aspect of vehicle safety, it is known to provide a vehicle with means to detect potential collisions and to take appropriate actions to avoid the same. For example, vehicles have been equipped with numerous types of sensors (e.g., infra-red sensors) which are able to broadcast radiation towards a potential obstacle (a tree, building, or another vehicle for example), receive radiation reflected from that obstacle, and determine that obstacle's distance and hence its potential as a collision hazard.
A developing technology in this area comprises antenna structures operating at or near 77 GHz frequencies. Such antenna structures include the ability to transmit and detect reflected 77 GHz radiation, and thus may be referred to as transceivers. A simple illustration of such a transceiver 12 mounted in a vehicle 10 is illustrated in FIG. 1 . The transceiver 12 may be mounted anywhere in the vehicle 10 so long as the transmission and detection of the radiation is not significantly impeded, and preferably may be mounted inside the bumper of the vehicle. In the specific example illustrated, the transceiver 12 is positioned in the front bumper of the vehicle allowing for assessment of potential hazards in front of the vehicle. As the broadcast radiation is preferably generally beam shaped, it is usually beneficial to cause the radiative beam to oscillate from left to right in front of the vehicle so as to “sweep” an arc-shaped sector in front of the vehicle. Using 77 GHz transceivers, the beam is usually swept between +/−10 degrees (θ) at a frequency of about 10 Hz or so, and has an effective distance for assessing potential hazards of approximately 100 meters. When such a transceiver 12 is incorporated into a vehicle 10 , potential collision hazards can be detected, which is useful in its own right as a safety feature, and is further useful in other respects, for example, as input to an adaptive cruise control system which automatically slows the car when hazards are detected at a certain distance.
FIGS. 2A and 2B show the basic components of a typical transceiver 12 in further detail, including a parabolic reflector dish 16 , a horn antenna 18 , relevant electronics as exemplified by a printed circuit board (PCB) 22 , and a substrate structure or housing 14 for mounting and/or housing the same. The PCB 22 generates and transmits the radiation 20 from the horn antenna 18 , and similarly receives reflected radiation from a potential collision hazard as noted above. The horn antenna 18 is located at a focal point of the parabolic reflective surface 16 a of the dish 16 such that radiation 20 broadcast from the horn antenna leaves the dish 16 in a generally horizontal beam, and similarly so that reflected radiation 20 is eventually focused back to the horn antenna 18 and the PCB 22 for detection. (The dish 16 as shown generally represents the “upper half” of a parabola). Other antenna configurations have been used with vehicular radar sensors, but using a parabolic antenna is generally preferred for producing a narrow beam for multiple object detection.
As noted earlier, the beam is swept (i.e., through angle θ) in any number of well known ways, for example, by causing the parabolic dish 16 to oscillate back and forth. Because such oscillation schemes are well known and not particularly important in the context of the invention, such details are not shown. However, it suffices to say that the dish 16 can be made to oscillate with respect to the housing 14 by mounting it thereto with springs or dampers to allow the dish to swivel, and by cyclically powering solenoids within the housing 14 to swivel the dish 16 by electromagnetic force.
Further details concerning the foregoing concepts and transceiver structures and controls can be found in U.S. Pat. Nos. 6,542,111; 6,646,620; 6,563,456; and 6,480,160, which are incorporated herein by reference in their entireties.
A major drawback to the collision detection transceiver 12 of the type illustrated is its cost, particularly as it related to the horn antenna 18 . As a three-dimensional waveguide, the horn antenna is generally rather complex to design and manufacture, as the angles, lengths and the other various dimensions of the waveguide must be specifically tailored to give optimum performance for the radiation 20 (i.e., at 77 GHz) in question. This accordingly adds significant cost to the transceiver 12 , which generally hampers use of the transceiver in vehicles that generally cannot be labored with substantial add-on costs. Moreover, from a functional standpoint, the use of the horn antenna adds additional structural complexity to the overall design of the transceiver assembly, as it essentially “sticks out” of the assembly, must be precisely coupled to the PCB 22 , is susceptible to damage and misalignment, etc.
In short, room exists to improve upon existing vehicular collision detection transceivers, and this disclosure presents solutions.
SUMMARY OF THE INVENTION
In one embodiment, an improved transceiver assembly for a vehicle capable of detecting potentially hazardous objects is disclosed. The transceiver assembly comprises a patch array feed antenna having an array of a plurality of patches for generating a beam and for detecting the beam as reflected from the potential hazards. The antenna is formed in or on a housing which also contains a parabolic dish that oscillates to sweep the beam of radiation towards the potential hazards outside of the vehicle. In a preferred embodiment, approximately 77 GHz radiation is generated from and detected by the antenna.
The antenna of the transceiver assembly is preferably located at a focus of a parabolic surface of the dish, and is formed on a printed circuit board (PCB). The PCB can include a ground plane underneath the patches of the antenna, and can include additional circuitry necessary to operate the antenna. The antenna may be integral with the housing, formed on the housing, positioned within the housing, or at least partially exposed through the housing, so long as the loss of signal through any materials present on the assembly is minimized.
The patches of the antenna are preferably located at different positions on the antenna in a manner to preferentially steer the generated beam toward the dish, and are all connected to a common feed. By slightly altering the lengths of the feedlines to the patches, the phases of the various patches can be altered, with the overall effect being that the beam generated by the antenna can be generally steered toward the parabolic dish at an acute angle of incidence with respect to a plane of the patches.
The transceiver assembly is preferably mounted to or within a vehicle, such as in its bumper. The reflected signals can be transformed into a signal indicative of the potential hazard, which may in turn be sent to a vehicle communication bus to reduce a speed of the vehicle in a cruise control application, for example. Alternatively, the signal indicative of the potential hazard can be broadcast to the user, either audibly, visually, or both.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the inventive aspects of this disclosure will be best understood with reference to the following detailed description, when read in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates use of a prior art collision detection system, in which an oscillating transceiver is incorporated into a bumper of a vehicle.
FIGS. 2A and 2B illustrate a prior art transceiver of the type illustrated in FIG. 1 incorporating the use of a horn antenna.
FIGS. 3A and 3B illustrate the improved transceiver, incorporating the use of a patch array feed antenna.
FIG. 4A illustrates an exemplary printed circuit board having the patch array feed antenna and other components, and FIG. 4B represents a cross sectional view through the printed circuit board.
DETAILED DESCRIPTION
FIGS. 3A and 3B illustrate an embodiment of an improved vehicular collision detection transceiver 40 which employs a patch array feed antenna 50 in lieu of the horn antenna 18 used in prior designs (see FIGS. 2A & 2B ). The patch feed antenna 50 works in a similar fashion to the horn antenna 18 , i.e., it is capable of broadcasting and receiving radiation 20 and hence is useful in the context of the disclosed vehicular collision detection transceiver. However, the design of the transceiver is simplified, and is made significantly less expensive, through the use of the patch array feed antenna 50 . As can be seen in FIG. 3B , and as will be made explained in further detail later, the patch array feed antenna 50 is preferably formed on the PCB (or more generically, “substrate”) 22 which includes the other circuitry needed for operation of the transceiver 40 . Such additional and well-known circuitry includes the oscillators or resonators necessary to form the 77 GHz radiation, other integrated circuits such as amplifiers, filters, a mixer for downconverting the detected beam as reflected from the objects, passive structures such as capacitors and inductors, and further preferably includes the processors necessary to process the detected reflected radiation to form a signal or signals which can be sent to the vehicle communication bus to indicate the detected potential hazard. The oscillators can directly create a signal at 77 GHz, or may operate at lower frequencies which are then multiplied up to 77 GHz. Because such circuitry and its manner of interfacing with a vehicle communication bus is well known, it is not shown for simplicity (see box 53 , FIG. 4A ).
In any event, through the use of the patch array feed antenna 50 , the use of an expensive and relatively mechanically-complex horn antenna is obviated. The design provides further benefits in that the patch array feed antenna 50 can be formed onto the same PCB 22 used in the transceiver for other purposes, as just noted, in effect combining the circuitry and antenna functions into a single substrate. Moreover, the transceiver is made sleeker in its profile, as no mechanical parts (aside from the dish 16 ) are made to protrude from the housing 14 , hence reducing alignment problems and potential damage that might result from protruding mechanical parts.
The patch array feed antenna 50 as formed in an exemplary embodiment on the PCB 22 is shown in further detail in FIGS. 4A and 4B . As shown, the antenna 50 is comprised of a plurality of patches 60 formed in an array (such as the 2-by-4 array shown). Each patch 60 's area is generally designed to resonate at the exemplary 77 GHz frequency, and in this regard, each patch is preferably designed as a quarter-wavelength resonator. Thus, at 77 GHz, the length of a given side of each patch (such as 60 a ) would be approximately 1 millimeter in length. Overall, the entirety of the patch array feed antenna 50 would therefore range from about 5 to 20 millimeters squared depending on the number of patches 60 used and their orientation. The traces interconnecting the patches in an exemplary embodiment can have a width 61 of approximately 120 microns, and each patch is preferred coupled to a common feed 67 . As one skilled in the art of antenna physics will understand, the length of the various traces is important to ensuring good resonance behavior on part of the patch array feed antenna 50 , as is further explained below. Other types of non-direct feed mechanisms can be used as well to energize the patches, such as those premised on coupling principles, such as are disclosed in Ramesh Garg, “Microstrip Antenna Design Handbook,” published by Artech House, pp. 28–29 (2001), which is incorporated herein by reference.
The other circuitry needed for operation of the transceiver 40 (such as the oscillators, tuners, receivers, etc.) is represented generally by circuit block 53 , as mentioned above. One exemplary integrated circuit in circuit block 53 is shown as integrated circuit 74 , which might comprise the oscillator for example. As shown, the integrated circuit 74 is preferably a “bare die,” i.e., an unpackaged integrated circuit. As one skilled in the art will understand, the use of bare dies are preferable when operating at high frequencies such as 77 GHz, as packaging the integrated circuits can add unwanted parasitic capacitance and inductance. As shown in FIGS. 4A and 4B , a connection is established between the integrated circuit 74 and the common feed 67 , which as shown comprises a bond wire as is used traditionally in semiconductor manufacturing. (Of course, additional integrated circuits could also be connected to the common feed 67 , but this is not shown for clarity). Although only one bond wire is shown, additional bond wires in parallel could be used and the use of such multiple connections is preferable to improve electrical coupling between the integrated circuit 74 and the common feed 67 . Other connecting means such as a ribbon bond could also be used, for example. Generally this connection should be as short, flat, and mechanically resilient as possible.
In one embodiment, the integrated circuit 74 is placed in a hole 75 in the PCB 22 , which can be milled in the PCB 22 . This allows the integrated circuit to be conductively epoxied to the ground plane 73 under the PCB 22 to improve the grounding stability of the patch array feed antenna 50 . Of course, the disclosed embodiment for mounting the integrated circuits 74 within circuit block 53 and for coupling the same to the common feed 67 are merely exemplary, and other means could be used as one skilled in the art will appreciate.
Once the PCB 22 is formed, care should be taken not to damage any exposed connections, such as the bond wires. Accordingly, the circuitry can be covered by a low-loss cap or lid to protect the components and connection, and/or appropriate recesses can be formed in the housing 14 to allow clearance for such components and connections. See, e.g., the above-incorporated patent application for further details. In one embodiment, the cap or lid can comprise the radome, discussed in further detail below. Such components may also be covered with a protective epoxy once formed, but this is less preferred as it might add additional capacitance and inductance to the circuitry and hamper performance.
The PCB 22 can also include a connector portion 51 suitable for connecting the PCB and its traces to an edge connector (not shown), which for example might couple to a vehicle communication bus (not shown). The various leads in the connector portion 51 would carry power, control and data (i.e., reflection data) between the PCB 22 and the vehicle in which the transceiver 40 is placed. For example, when a reflected signal is detected through its resonance of the antenna 50 , that signal is preferably processed at circuit block 53 and causes a signal (i.e., indicator) to be sent to a lead or leads on the connector portion to inform the vehicle of the detected potential hazard. Such signal can then be sent by the vehicle communication bus to the control system of the vehicle, for example, to cause the vehicle to reduce its speed. Or, such signal might merely be audibly broadcast to a user of the vehicle (e.g., a “beep” or a warning voice message), or displayed to the user (e.g., a lit LED or an indication on an interface screen), or both. Alternatively, processing of the reflected signals can be performed off of the PCB 22 .
Generally, radiation 20 will emit from each patch 60 orthogonal to its surface (i.e., straight upwards). See David M. Pozar, “Microwave Engineering,” published by Addison-Wesley, pp. 183–184 (1990), which is incorporated herein by reference. However, in a preferred embodiment, the patches 60 of the patch array feed antenna 50 provide the ability to “steer” the emitted or received beam of radiation 20 . As can be best seen from FIG. 3B , it is desirable that the antenna direct as much energy as possible toward the parabolic dish 16 . Thus, as shown in that Figure, it is desired to generally focus the radiation to the left, as radiation emitted to the right or upwards will generally be “lost” and unusable in the formation of a horizontal beam from the dish 16 . Such steering from the patch array feed antenna 50 is made possible in any of several different ways as one skilled in the art will recognize, but in a preferred embodiment steering is accomplished by altering the phase at which each patch 60 radiates, which in turn can be dictated by the lengths of the traces that feed them.
Accordingly, each of the patches 60 is laid out at slightly different distances or locations on the PCB 22 . For example, consider traces 63 a and 63 b in FIG. 4A . If it is desired to generally steer the radiation to the left of the PCB 22 , the phases at which the patches 60 connected to these traces (i.e., 60 a – 60 d ) can be varied by adjusting the lengths of the traces (i.e., feedlines) such that the length of trace 63 b is slightly longer or shorter (e.g., by tens of microns) than the length of trace 63 a . The overall effect, when constructive and destructive interference of the radiation from the patches 60 a–d is considered, is that the radiation will generally be directed towards the left as desired, with the acuteness of the angle of incidence ( 70 , FIG. 3B ) towards the dish 16 being dictated by the difference in distance. Specific details regarding the various lengths of traces to be used is not necessary, as one skilled in the art of antenna physics well understands how to steer radiation from a patch array feed antenna, and recognizes that some degree of routine experimentation might be required to achieve the desired result, considering such factors as trace width and thickness, the dielectric constant of the PCB 22 , etc.
A cross section of the PCB 22 is shown in FIG. 4B . In a preferred embodiment, a high quality PCB material with a low dielectric constant and a low loss tangent is desired given the high frequencies with which the PCB 22 will be used. Thus, standard FR 4 PCB materials may not be acceptable to properly function at 77 GHz without significant loss of signal. Instead, the PCB 22 may be formed of Duroid™ material (i.e., a glass microfiber reinforced polytetrafluoroethylene (PTFE) composite) or other high frequency laminates, such as is available from Rogers Corporation of Rogers Connecticut. (See http://www. rogerscorporation.com/a cm/index.htm). Additionally, ceramic substrates (such as low-temperature co-fired ceramics), liquid crystal polymers substrates, and or foam substrates can be used as the material for PCB 22 . Ideally, the thickness 57 of the PCB 22 is approximately 2 mils thick. The metallic traces and patches 60 formed on the PCB 22 are preferably corrosion resistant which is desirable given the harsh conditions in which the transceiver 40 will be used in a vehicular environment. Accordingly, such traces and their associated patches 60 are preferably gold, or copper, or at least gold coated. The thickness of the top traces and patches 56 and the thickness of the ground plane 57 can be approximately 10 to 20 microns, and obviously is not drawn to scale in FIG. 4B .
Although a preferred embodiment is described, one skilled in the art of antenna physics will understand that the desired functionality of the patch array feed antenna 50 can be achieved in many different ways. The number of patches, their size, the nature in which they are arrayed, their respective distances, the materials used to form them, the frequencies at which they resonate, etc., can be easily varied to arrive at any number of variations. The antenna could be in the form of another well known planar antenna, such as a printed dipole, so long as the radiation pattern is perpendicular to the surface but has a wide beam suitable for steering at acute angles. Accordingly, none of these parameters is crucial, and the invention should not be understood as limited to any of these particulars as disclosed. Moreover, while particularly useful in the broadcast and detection of 77 GHz radiation, the disclosed patch array feed antenna 50 can be used with (and tailored for) other frequencies as well. For example, future transceiver assemblies may use even higher frequencies, such as 140 GHz, 220 GHz, or any other publicly available band, with the use of such higher frequencies allowing the antenna to be made smaller and/or more directive.
The overall construction of the vehicular collision detection transceiver 40 is likewise susceptible to various modifications. As shown in FIG. 3B , only that portion 22 b of the PCB 22 containing the patch array feed antenna 50 is generally exposed through the housing 14 , while other portions 22 a of the PCB 22 (i.e., those containing the other necessary circuitry 53 ) are covered. This is generally preferred to reduce loss between the antenna 50 and the dish 16 while still protecting the circuitry. However, this is not strictly necessary, as the entirety of the PCB 22 , including portion 22 b can be covered by the housing 14 so long as the housing is not generally reflective (i.e., metallic) in a manner to interfere with the transceiver 40 's use. In this regard, it should also be noted that it is preferable that the bumper or other structure on the vehicle in which the transceiver is placed (mounting not shown) be similarly transmissive to the radiation emitted from and detected by the transceiver. (For example, the bumper would preferably be free of metallic paint). Of course, some degree of loss is inevitable and permissible. Ultimately, the entirety of the transceiver 40 would be encapsulated within a low-loss radome (not shown) to protect the transceiver from the harsh conditions in which it will operate within a vehicle, as is well known. As alluded to earlier, if exposed circuitry and/or connections are present, care should be taken to mount the PCB 22 to or within the housing 14 in such a manner as to mechanically protect such structures, such as by the use of recesses, spacers, protective caps or lids, etc.
A “patch” as used herein should be understood as referring to any planar element capable of radiating orthogonally to the substrate on which it is formed. Thus, a “patch” need not be strictly rectilinear is shape, but includes shapes such as lines, squares, rectangles, and other more complex shapes such as spirals or shapes containing notches capable of radiating orthogonally to the substrate. Consistent with this understanding, a “patch” should also be understood to refer to the absence of metallization, and can actually refer to a portion of a “slot antenna,” such as those that comprise a slot in the ground plane of a grounded substrate, including printed dipole antennas and microstrip traveling-wave antennas. See Ramesh Garg, “Microstrip Antenna Design Handbook,” published by Artech House, pp. 8–14 (2001), which is incorporated herein by reference.
While preferably disclosed as a having a parabolic reflector dish 16 , one skilled in the art will understand that the disclosed transceiver 40 may be formed using other types of reflectors. For example, the dish 16 may be replaced by a “reflectarray,” which essentially constitutes a plurality of patches tuned to reflect radiation similarly to a parabolic antenna. See Pozar, “Design of Millimeter Wave Microsrtip Reflectarrays,” IEEE Transactions on Antennas and Propagation, Vol. 45, No. 2, pp. 287–296 (February 1997), which is incorporated herein by reference.
The disclosed antenna could also be designed for specific polarizations of the radiation 20 , which is useful because some objects being detected might reflect certain polarizations differently. See Ramesh Garg, “Microstrip Antenna Design Handbook,” published by Artech House, pp. 493–497 (2001), which is incorporated herein by reference.
Although disclosed in the context of being useful within a vehicle, the disclosed transceiver assembly can be used in other contexts as well to detect the presence of objects other than those present while driving.
It should be understood that the inventive concepts disclosed herein are capable of many modifications. To the extent such modifications fall within the scope of the appended claims and their equivalents, they are intended to be covered by this patent.
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An improved transceiver assembly for a vehicle for detecting potentially hazardous objects is disclosed. The transceiver assembly preferably comprises a patch array feed antenna having an array of a plurality of patches for generating a beam and for detecting the beam as reflected from the potential hazards. The antenna is formed in or on a housing which also contains a parabolic dish that moves to sweeps the beam of radiation towards the potential hazards outside of the vehicle. In a preferred embodiment, approximately 77 GHz radiation is generated from and detected by the antenna.
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FIELD OF THE INVENTION
The present invention relates to puncture-resistant microporous materials (e.g., films and/or membranes). In another aspect the invention relates to articles made from microporous materials and to methods for preparing such materials and articles.
BACKGROUND OF THE INVENTION
Microporous films, sheets, and membranes are materials that have structures which enable fluids to pass readily through them. These materials have pores whose effective size typically is at least several times the mean free path of the flowing molecules, namely from several micrometers down to as low as about 100 Angstroms. Sheets made from the materials generally are opaque, even when made from an originally transparent material, because the surfaces and internal structure scatter visible light.
Microporous membranes enjoy utility in a wide range of divergent applications, including use in the filtration of solid materials, ultrafiltration of colloidal matter, use as diffusion barriers or separators in electrochemical cells and uses in the preparation of synthetic leathers and fabric laminates. The latter requires the membranes to be permeable to water vapor but substantially impermeable to liquid water when used to prepare such articles as shoes, raincoats outer wear, camping equipment, and the like. Microporous membranes also are utilized in the filtration of antibiotics, beers, oils, bacteriological broths, and for the analysis of air, microbiological samples, intravenous fluids and vaccines. Surgical dressings, bandages and other fluid transmissive medical articles likewise incorporate microporous membranes and films. Microporous membranes also are commonly employed as battery separators.
For more particularized applications microporous membranes may be laminated onto other articles to make laminates of specialized utility. Such laminates may include, for example, a microporous layer laminated to an outer shell layer to make a particularly useful garment material. Microporous membranes may also be utilized as a tape backing to provide such products as vapor transmissive wound dressing or hair setting tapes and the like.
A number of methods for making microporous films and membranes are taught in the art. One of the most useful methods involves thermally induced phase separation. Generally such a process is based on the use of a polymer that is soluble in a diluent at an elevated temperature but that is insoluble in the diluent material at a relatively lower temperature. The so-called "phase transition" can involve a solid-liquid phase separation, a liquid-liquid phase separation or a liquid to gel phase transition. Examples of such methods are described in U.S. Pat. Nos. 4,247,498, 4,539,256, 4,726,989, and 4,867,881.
Typically, state-of-the-art processes that employ normally melt-processable polymers produce films and membranes with relatively low puncture resistance. To overcome this limitation for applications where mechanical strength and puncture resistance are desirable, a component of an ultra-high molecular weight polyolefin typically is added to the film or membrane to boost its mechanical integrity and puncture strength. U.S. Pat. No. 5,051,183 (Takita et al.), for example, describes making microporous films having at least one percent by weight of an ultra-high molecular weight polyolefin. While the addition of ultra-high molecular weight materials can favorably address problems of mechanical integrity, blends containing these additions are not normally melt-processable and must further incorporate plasticizers to become melt-processable. Thus use of blends containing such additions generally adds complexity and cost to processing techniques.
SUMMARY OF THE INVENTION
Briefly, in one aspect, the present invention provides puncture resistant microporous materials made of melt-processable semi-crystalline thermoplastic polymers. These microporous materials can be produced at relatively high rates and at low cost. Accordingly, in one aspect, the present invention provides a method of making microporous material, the method comprising:
(a) melt blending to form a substantially homogeneous mixture comprising:
(i) from about 25 to about 60 parts by weight of a melt-processable, semi-crystalline thermoplastic polymer component; and
(ii) from about 40 to about 75 parts by weight of a second component comprising either (1) a compound that is miscible with the thermoplastic polymer component at a temperature above the melting temperature of the thermoplastic polymer component but that phase separates from the thermoplastic polymer component when cooled below the crystallization temperature of the thermoplastic polymer component or (2) a compatible liquid that is miscible with the thermoplastic polymer component at a temperature above the liquid-liquid phase separation temperature but that phase separates from the thermoplastic polymer component when cooled;
(b) forming a shaped material of the melt blended mixture;
(c) cooling the shaped material to a temperature at which phase separation occurs between the compound or compatible liquid and the thermoplastic polymer component through either (1) crystallization precipitation of the thermoplastic polymer component or (2) liquid-liquid phase separation; and
(d) stretching the shaped material in at least two perpendicular directions to an area expansion ratio of greater than nine to provide a network of interconnected pores; and
(e) removing the compound or compatible liquid to provide a microporous material having a puncture resistance of at least 350 g/25 microns.
In a second aspect, the invention provides a microporous material comprising a melt-processable, semi-crystalline thermoplastic polymer where the thermoplastic polymer is miscible in a compound or compatible liquid when heated above the melting temperature of the thermoplastic polymer or the liquid-liquid phase separation temperature and phase separates from the compound or compatible liquid when cooled, where the material is stretched in at least two perpendicular directions to an area expansion ratio of greater than nine, and where the material has a puncture resistance of at least 350 g/25 micrometers. Articles, including membranes, films and sheets made of the microporous materials also are described.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The microporous materials of the invention are made using melt-processable polymers. The melt-processed materials are made microporous by phase separating from the material either (1) a compound that is miscible with the thermoplastic polymer component at a temperature above the melting temperature of the thermoplastic polymer component but that phase separates from the polymer component when cooled below the crystallization temperature of the component or (2) a compatible liquid that is miscible with the thermoplastic polymer component at a temperature above the liquid-liquid phase separation temperature but that phase separates from the polymer when cooled.
The term "normally melt processable" or simply "melt processable" is used herein to refer to polymers that are melt-processable under ordinary melt-processing conditions using conventional extrusion equipment without the need for plasticizer addition.
The term "melting temperature" is used to refer to the temperature at or above which the polymer component in a blend with a compound or a compatible liquid will melt.
The term "crystallization temperature" refers to the temperature at or below which the polymer component in a blend with a compound, will crystallize.
The term "liquid-liquid phase separation temperature" is used to refer to the temperature at or below which a melt of a mixture of a polymer and a compatible liquid, i.e., a homogeneous polymer-melt, phase separates by either binodal or spinodal decomposition.
The term "compatible" or "a compatible mixture" refers to a material capable of forming a fine dispersion (less than 1 micron in particle size) in a continuous matrix of a second material or capable of forming an inter-penetrating polymer network of both materials.
Polymers useful in the present invention are normally melt-processable, and the melt-processability of many common individual polymers can be predicted from melt flow indices. Normally melt-processable polymers are those that have a sufficiently low melt viscosity, i.e., a sufficiently high melt flow index, that they can be extruded through either a single screw extruder or a twin screw extruder without the aid of plasticizing materials. The actual melt flow index that is suitable depends on the type of polymer. Examples of some of the more common polymers of interest are as follows. High density polyethylene, for example, is considered melt-processable if it has a melt flow index above 4 dg/min (ASTM D1238-90b, Condition F, HLMI); and ethylene alpha-olefin copolymer and ethylene vinylalcohol copolymer are considered melt processable if they have a melt flow index above 0.5 dg/min (ASTM D1238-90b, Condition E). Polypropylene is considered melt-processable if it has a melt flow index above 0.2 dg/min (ASTM D1238-90b, Condition 1). Poly(ethylene chlorotrifluoro ethylene) is considered melt-processable if it has a melt flow index above 1.0 dg/min (ASTM D1238-90b, Condition J). Poly(vinylidene fluoride) is considered melt-processable if it has a melt flow index above 0.2 dg/min (ASTM D1238-90b, Condition L). Polymethylpentene is considered melt-processable if it has a melt flow index above 5 dg/min (ASTM D1238-90b, Condition 260 C, 5 kg load). Compatible blends of melt-processable polymers also are melt-processable. In contrast, classes of polymers with melt flow indices far below values considered melt-processable for that polymer class generally are special grades that are not normally melt-processable and must be processed using special techniques, such as ram extrusion, or must be plasticized to enable processing with a conventional extrusion equipment. Processing the polymer grades that are not normally melt-processable with a plasticizer requires longer residence times in the extruder to obtain desirable melt homogeneity and higher concentrations of a compound or compatible liquid in the melt to reduce extruder energy requirements. As a result, equipment productivity is significantly limited, the production costs increased, and dangers of thermal degradation is increased.
Useful polymers also are those that can undergo processing to impart a high biaxial orientation ratio in a manner that enhances their mechanical integrity, and are semi-crystalline in nature. Orienting semi-crystalline polymers significantly improves the strength and elastic modulus in the orientation direction, and orientation of a semicrystalline polymer below its melting point results in extended chain crystals with fewer chain folds and defects. The most effective temperature range for orienting semicrystalline polymers is between the alpha crystallization temperature of the polymer and its melting point. The alpha crystallization temperature (or alpha transition temperature) corresponds to a secondary transition of the polymer at which crystal sub-units can be moved within the larger crystal unit.
Preferred polymers therefore are those that exhibit an alpha transition temperature and include, for example: high density polyethylene, linear low density polyethylene, ethylene alpha-olefin copolymers, polypropylene, poly(vinylidene fluoride), poly(vinyl fluoride), poly(ethylene chlorotrifluoro ethylene), polyoxymethylene, poly(ethylene oxide), ethylene vinylalcohol copolymer, and compatible blends thereof. Blends of one or more "compatible" polymers may also be used in practice of the invention. In case of compatible blends it is not necessary that both components exhibit an alpha crystallization temperature and if liquid-liquid phase separation is used, the minor component in the blend need not to be even semi-crystalline. Particularly preferred polymers have melting temperatures greater than 140° C. (e.g., polypropylene) and blends of such polymers with lower temperature melting polymers.
Miscibility and compatibility of polymers are determined by both thermodynamic and kinetic considerations. Common miscibility predictors for non-polar polymers are differences in solubility parameters or Flory-Huggins interaction parameters. For polymers with non-specific interactions, such as polyolefins, the Flory-Huggins interaction parameter can be calculated by multiplying the square of the solubility parameter difference by the factor (V/RT), where V is the molar volume of the amorphous phase of the repeated unit V=M/ρ (molecular weight/density), R is the gas constant, and T is the absolute temperature. As a result, Flory-Huggins interaction parameter between two non-polar polymers is always a positive number. Thermodynamic considerations require that for complete miscibility of two polymers in the melt, the Flory-Huggins interaction parameter has to be very small (e.g. less than 0.002 to produce a miscible blend starting from 100,000 weight-average molecular weight components at room temperature). It is difficult to find polymer blends with sufficiently low interaction parameters to meet the thermodynamic condition of miscibility over the entire range of compositions. However, industrial experiences suggest that some blends with sufficiently low Flory-Huggins interaction parameters, although still not miscible based on thermodynamic considerations, form compatible blends.
Unlike miscibility, compatibility is difficult to define in terms of exact thermodynamic parameters, since kinetic factors, such as melt processing conditions, degree of mixing, and diffusion rates can also determine the degree of compatibility.
Some examples of compatible polyolefin blends are: high density polyethylene and ethylene alpha-olefin copolymers; polypropylene and ethylene propylene rubber; polypropylene and ethylene alpha-olefin copolymers; polypropylene and polybutylene.
In the presence of a common diluent or oil component that is miscible with all polymers in a blend above their melting temperatures, the thermodynamic requirements for miscibility relax. Two polymers with a Flory-Huggins interaction parameter that is significantly greater than the critical value for miscibility in a binary system, can still be miscible in a melt comprising a ternary system with a common solvent, at least over a range of compositions.
Compatibility affects the range of useful polymer concentrations when polymer blends are employed. If the polymers are incompatible, that range of compositions can be quite narrow, restricted to very low polymer concentrations, and of minimal practical usefulness in making the inventive articles. However, if polymers are compatible, a common solvent can promote their miscibility into the composition regions of much higher polymer concentrations, thus allowing the use of common processing techniques such as extrusion to make articles of this invention. Under these conditions, all components in the melt are miscible and phase-separate by crystallization precipitation or liquid-liquid mechanism upon cooling below the phase separation temperature. The rate of cooling is quite rapid (preferably sufficient so that the melt-blended solution cools below the phase boundary in 30 seconds or less) and controlled by the process conditions that minimize the size of phase-separated microdomains and provides uniformity on a microscopic level.
Compatibility also affects film uniformity. Cast films that are made from compatible blends by the method of this invention are transparent which confirms the uniformity on a microscopic level. This uniformity is of great importance for successful post-processing: films with a lesser degree of uniformity made from incompatible polymers break easily during stretching. Film uniformity is also important in some applications, such as thermal shutdown battery separators, for which reliable shutdown performance on a microscopic level is desirable.
Materials useful as the second component are those that form a solution with the chosen melt-processable thermoplastic polymer or polymer mixture at an elevated temperature to form a solution but that also permit the components to phase separate when cooled. This second component may sometimes be referred by shorthand simply as the "blending compound" or the "diluent." Useful blending compound materials include (1) those mentioned as useful compounds in Shipman, U.S. Pat. No. 4,539,256, incorporated herein by reference, (2) those mentioned as useful compatible liquids in Kinzer, U.S. Pat. No. 4,867,881, incorporated herein by reference, and (3) additional materials such as, dodecyl alcohol, hexadecyl alcohol, octadecyl alcohol, dicyclohexylphthalate, triphenyl phosphate, paraffin wax, liquid paraffin, stearyl alcohol, o-dichlorobenzene, trichlorobenzene, dibutyl sebacate, and dibenzyl ether.
Compounds suitable to make the microporous material of the invention by crystallization precipitation are liquids or solids at room temperature. These compounds are also materials in which the crystallizable thermoplastic polymer will dissolve to form a solution at a temperature above the melting temperature of the thermoplastic polymer component but that will phase separate on cooling at or below the crystallization temperature of the thermoplastic polymer component. These compounds preferably have a boiling point at atmospheric pressure at least as high as the melting temperature of the thermoplastic polymer. Compounds having lower boiling points may be used in those instances where superatmospheric pressure may be employed to elevate the boiling point of the compound to a temperature at least as high as the melting temperature of the thermoplastic polymer component.
Particularly useful with polypropylene are mineral oil, dioctylphthalate, or mineral spirits. Mineral oil and mineral spirits are examples of mixtures of blending compounds since they are typically blends of hydrocarbon liquids. These are especially useful in some of the polymer mixture of the present invention.
For microporous materials made by liquid-liquid phase separation, a compatible liquid is used to make up the solution in the preparation of the microporous material. The compatible liquid is a liquid or solid material at room temperature that is capable of forming a solution with the thermoplastic polymer when heated above the liquid-liquid phase separation temperature and which phase separates from the polymer by liquid-liquid phase separation, rather than crystallization precipitation, on cooling. The compatibility of the liquid with the thermoplastic polymer can be determined by heating the polymers and the liquid to form a clear homogeneous solution. If a solution of the polymers and the liquid cannot be formed at any liquid concentration, then the liquid is inappropriate for use with those polymers. In practice, the liquid used may include compounds which are solid at room temperature but liquid at the melt temperature of the thermoplastic polymer component.
It will be understood that the operability of a specific liquid with a given thermoplastic polymer cannot be predicted with absolute certainty. Certain guidelines can, however, be set forth. For non-polar thermoplastic polymers, non-polar organic liquids with similar room temperature solubility parameters generally are useful at the solution temperatures. Similarly, polar organic liquids generally are useful with polar polymers. Blends of two or more liquids can be used as the compatible liquid as long as the selected thermoplastic polymer is soluble in the liquid blend at the liquid-liquid phase separation temperature and the solution formed separates by liquid-liquid phase separation on cooling. One component of such compatible blends also can be a non-solvent for a selected polymer as long as it is mixed with at least one effective solvent in amounts sufficient to reduce its solvency and induce, upon cooling, liquid-liquid phase separation instead of crystallization precipitation. When the selected thermoplastic semi-crystalline polymer component is polypropylene, esters such as dibutyl phthalate, ethers such as dibenzyl ether, and blends of mineral oil and non-ionic surfactants such as PEG-400-dilaurate are particularly useful as the compatible liquid.
Where two or more thermoplastic polymers are blended together to form a first polymer component comprising a polymer mixture, the compatible liquid can phase separate from one component of the compatible polymer mixture by liquid-liquid phase mechanism, while phase separating from the other component of the compatible polymer mixture by crystallization precipitation. In that case, hybrid structures form, and these structures can resemble both of the described two structures; i.e., that obtained by crystallization precipitation or liquid-liquid phase separation, respectively. Thus, for example, when a first polymeric component is polypropylene and a second polymeric component is polybutylene, an ester such as dioctyl phthalate is particularly useful to obtain a hybrid structure.
The microporous materials of the invention may also contain, in addition to compounds described above, conventional fillers or additive materials in limited quantity so as not to interfere with the formation of the microporous material, and so as not to result in unwanted exuding of the additive. Such additives may include anti-static materials, dyes, plasticizers, UV absorbers, nucleating agents, anti-oxidants, and the like. The amount of additive is typically less than 10% of the weight of the polymeric mixture, preferably less than 2% by weight.
A melt solution may be prepared by mixing the thermoplastic polymer component and the blending compound under agitation such as that provided by an extruder and heating until the temperature of the mixture is above (1) the melting point of the polymer component, or (2) the liquid-liquid phase separation temperature of the mixture. At this point the mixture becomes a melt solution or single phase.
The melt solution is prepared by mixing the polymer and blending compound or compatible liquid in a continuous mixing device such as an extruder. Preferably, the blending compound is added after the polymer component is melted. Once the melt solution is mixed sufficiently to make a homogeneous melt, it is shaped in a form of a film or a sheet by a flat sheet or film die or by an annular die (as in a blown film line).
Cooling of the shaped article occurs by contacting the shaped material with a casting wheel, a water bath, or with air. Cooling causes the phase separation to occur between the blending component and the thermoplastic polymer component. This may occur either by crystallization precipitation of the polymer component to form a network of polymer domains or by a liquid-liquid phase separation to form cells of a polymer-lean phase. It will be understood that by either method the rate of crystallization must be sufficient to achieve the overall desired number of crystal sites. The crystallization rate is impacted by known processing conditions, and in those cases where the rate of crystallization is excessively slow additional factors must be considered, such as increased heat transfer (i.e., faster quench rate) and/or the addition of nucleating agents.
Sufficient stretching or orientation is needed to achieve improved puncture resistance over what has been known for microporous films made with normally melt processable polymers. The shaped material or film first is stretched biaxially, i.e. along at least two perpendicular directions. To achieve adequate orientation of the semi-crystalline thermoplastic polymer component, the film must be treated to a temperature above the alpha crystallization temperature and must be stretched enough to orient the mobile crystal structures. The most effective temperature range for orienting semicrystalline polymers is between the alpha crystallization temperature of the polymer and its melting point. In the presence of a compound or a compatible liquid that is miscible with a semicrystalline polymer above the melting or liquid-liquid phase separation temperature, the alpha transition temperature may reduce, allowing orientation to be carried out at a temperature below the alpha transition temperature of the pure polymer. Above the alpha crystallization temperature lamellar slip in larger crystal units, such as spherulites, occurs and extended chain crystals form. It is difficult to effectively orient polymers that do not have the alpha transition to any great extent because their crystal segments cannot be easily rearranged into an aligned state. The biaxial stretching may be performed either in sequentially or simultaneously. Sequential stretching is carried out by drawing the films with a length orienter and a tenter (i.e., orienting down-web and cross-web respectively). Simultaneous stretching is carried out by drawing the film in both directions at the same time. Although the degree of stretch may be the same or may be different in each direction, the film preferably is stretched to greater than nine times its original area, preferably at least 15 times, and more preferably at least 25 times. The resulting puncture resistance is at least 350 g/25 μm, preferably at least 400 g/25 μm, and more preferably at least 500 g/25 μm. The shaped material lacks air voids at this stage and achieves air voids through washing.
Microporosity is achieved by removing the blending compound or diluent through a removal step after the biaxial orientation. The removal may be carried out by extraction or by using other known methods.
Generally the pore size and percent void volume of the stretched and washed microporous material are determined by the amount of blending compound or compatible liquid used to make it. Preferably from 40 to 75 parts of a compound or from 40 to 75 parts of a compatible liquid are used per 100 parts of total composition. As less blending compound or compatible liquid is used, the porosity and pore interconnectivity generally decrease. As more blending compound or compatible liquid is used, the porosity and pore interconnectivity generally increase, but mechanical properties (e.g., tensile properties and puncture resistance) generally decrease. Porosity, pore interconnectivity, and mechanical properties are, however, also influenced to some extent by polymer types, component concentration, processing conditions (e.g., quenching rate and/or stretching temperature) and by the presence or absence of a nucleating agent. Thus, judicious selection of polymer materials and concentrations, blending compound or compatible liquid concentrations, and processing conditions will result in desired porosity, pore interconnectivity, and mechanical properties.
The microporous film can be thermally annealed after removal of the blending compound or compatible liquid to achieve improved dimensional stability. Also after the blending compound or compatible liquid has been removed, the microporous material or film may be imbibed with various fillers to provide any of a variety of specific functions, thereby providing unique articles. For example, the imbibing material or filler may be a liquid, solvent solution, solvent dispersion or solid. Such filler may be imbibed by any of a number of known methods which results in the deposition of such fillers within the porous structure of the microporous sheet. Some imbibing materials are merely physically placed within the microporous sheet. In some instances, the use of two or more reactive components as the imbibing materials permits a reaction within the microporous sheet structure. Examples of imbibing material include antistatic agents, surfactants, and solid particulate material such as activated carbon and pigments.
A multi-layer microporous material or film of the present invention may be made employing the above-described microporous material as a layer with at least one additional porous layer. By way of example, in a three-layer system the above-described porous layer is preferably the center layer sandwiched by, i.e., in between the additional porous layers.
The additional porous layers may include the same porous layer above described, namely, the phase-separated polymeric film or may also include a crystallization phase-separated, melt-processible polymer such as described in U.S. Pat. No. 4,539,256, or a porous layer comprising a liquid-liquid phase-separated, melt-processible polymer as described in U.S. Pat. No. 4,867,881.
The additional porous layers may be prepared by melt-blending solutions such as described in U.S. Pat. Nos. 4,539,256 and 4,867,881, the former describing a melt blend solution of a compound with a crystallization phase-separated, melt-processible polymer and the latter describing a melt blend solution of a liquid-liquid phase-separable, melt-processible polymer and a compatible liquid.
The multi-layer film may be formed by coextrusion of the two or more polymer compositions followed by cooling to cause phase separation and then orientation of the multi-layer film to form a porous film structure as previously described. The coextrusion may employ a feedblock or a multi-manifold die. The multi-layer film may alternatively be made by laminating one or more of the layers together.
The microporous materials or multi-layer films of the present invention may be employed in any of a wide variety of situations wherein microporous structures may be utilized. They find particular utility as battery separators.
EXAMPLES
Test Methods
Gurley Air Flow:
Gurley air flow is a measurement of time in seconds required to pass 10 cc of air through a film according to ASTM D 726-58 Method A using a 6.5 mm 2 orifice. A value of greater than 10,000 sec/10 cc is assigned if the Gurley timer does not start 15 minutes after the start of the test.
Puncture Resistance:
Puncture resistance is a measurement of the peak load required to puncture a perimeter restrained film as in AS° FM F-1306-90. The specimen clamping fixture holds the sample by compression at the annular region between two circular plates. The plates provide a 12.7-mm diameter exposed section of film. The penetration probe is a cylindrical 2-mm diameter probe with a 1-mm radius tip. The penetration probe is advanced at a rate of 2 mm/s and the maximum load before the film puncture is recorded. Values are reported in grams per unit of film thickness.
Porosity:
Porosity is a value calculated from the measured bulk density and polymer density using the following equation:
Porosity=(1-bulk density/polymer density)×100
The bulk density is determined by dividing the weight of a 47 mm diameter sample containing eight film layers with its thickness and accounting for its area conversion factor.
Tensile Strength:
Tensile strength at break is a value measured according to ASTM D 882-95a using an Instron™ model 1122 under the following conditions: jaw gap of 25 mm, jaw speed of 500 mm/min, and sample width of 25 mm.
Pore Size:
This value is the average pore diameter as determined by nitrogen sorption using, Quantachrome Autosorb™ Automated Gas Sorption System.
Example 1 and Comparative Example 1
Various microporous films were made to illustrate the effect of stretch ratios and order of process steps on puncture resistance.
In Example 1 and in Comparative Example 1, a normally melt-processable polymer component (high density polyethylene available under the trade designation of HYA-021 from Mobil Chemical Co.) with a melt flow index of 5.0 dg/min (ASTM D1238-90b, Condition F, HLMI) and a weight-average molecular weight of 226,900 was fed into the hopper of a 25 mm twin-screw extruder. A compound component, mineral oil (available under a trade designation Amoco White Mineral Oil #31) having a viscosity of 60 centistokes (ASTM D445-96 at 40° C.), was introduced into the extruder through an injection port at a rate to provide a composition of 45% by weight polymer component and 55% by weight compound component. The polymer and compound component were melt blended in the extruder, and the melt was fed into a coat-hanger die to form a sheet and cast on a cooled wheel to make a 305-micrometer thick film. Samples A-H of the cast film of Example 1 were first cut into 4.8-cm×4.8-cm squares and biaxially stretched, either sequentially or simultaneously, in ratios ranging from 4×4 to 7×7 (machine direction×cross-web direction) as shown in Table 1. Stretching was done at a rate of 20% per second while the film was at a temperature of 100° C. Following stretching, the samples were heat set under restraint for 30 seconds at 105° C. The samples were then washed under restraint in dichlorotrifluoroethane and dried.
The cast film of Comparative Example 1 was prepared in the same manner as the film of Example 1, except that it was washed under restraint in dichlorotrifluoroethane prior to stretching. Samples C1A-C1H then were cut and stretched in the same manner as the film in Example 1.
The cast film of Comparative Example C1I was prepared in the same manner as the film of Example 1. except that it was sequentially stretched 3×3.
The cast film of Comparative Example C1J was prepared in the same manner as the film of Comparative Example C1I, except that it was washed under restraint in dichlorotrifluoroethane prior to stretching and was heatset at 115° C. for 60 seconds.
The samples were tested for thickness, Gurley air flow, puncture resistance, porosity and tensile strength at break (MD/CD). All values are reported in the Table 1.
TABLE 1______________________________________ Resis- Thick- Gurley tance Stretch Ratio ness (sec/ (g/ Porosity TensileSample (MD × CD) (μm) 10 cc) 25 μm) (%) (kg/cm.sup.2)______________________________________1A 4 × 4 seq 25 602 417 35 850/--1B 5 × 5 seq 18 460 563 32 1201/10001C 6 × 6 seq 13 288 722 33 --/12001D 7 × 7 seq 10 252 878 33 --/13001E 4 × 4 sim 28 678 365 34 --/7201F 5 × 5 sim 20 567 488 33 960/--1G 6 × 6 sim 15 254 645 38 1000/11001H 7 × 7 sim 10 226 838 34 1500/1300C1A 4 × 4 seq 55 47 154 70 410/320C1B 5 × 5 seq 48 27 191 76 320/320C1C 6 × 6 seq 38 18 175 78 380/290C1D* 7 × 7 seq -- -- -- -- --C1E 4 × 4 sim 35 92 288 57 490/480C1F 5 × 5 sim 28 74 332 63 550/470C1G 6 × 6 sim 21 61 347 62 670/580C1H* 7 × 7 sim -- -- -- -- --C1I 3 × 3 seq 45 1060 248 36 650/500C1J 3 × 3 seq 50 165 228 50 450/430______________________________________ *film samples broke while stretching. "sim" refers to simultaneous stretching "seq" refers to sequential stretching
Example 2
A microporous film was made to illustrate the effect of a different polymer component to blending compound ratio and to illustrate the effect of an unbalanced stretch ratio on film properties.
A high density polyethylene identical to that used in Example 1 was fed into a hopper of a 40 mm twin-screw extruder. Mineral oil was introduced into the extruder to provide a composition of 40% by weight polymer component and 60% by weight blending compound. The overall flow rate was 11.4 kg/hr, the mixture of polymer and blending compound was maintained at a temperature of 204° C. during the extrusion, the casting roll was maintained at 66° C. and the film was stretched 6×11 at 104° C. in the machine direction followed by 4.2×1 at 113° C. in the cross-web direction, followed by continuous washing in dichlorotrifluoroethane and drying.
The sample was tested for thickness, Gurley air flow, puncture resistance, porosity and pore size. Thickness was 30 μm, Gurley was 268 sec/10 cc, puncture resistance was 463 g/25 μm, porosity was 49% and pore size was 0.03 μm.
Example 3
A microporous film was made to illustrate the effect of a different type of polymer component on film properties and to illustrate a three layer extrusion technique.
The high density polyethylene used in Example 1 was fed into a hopper of a 40 mm twin-screw extruder. A blending compound component (White Mineral Oil #31) was introduced into the extruder to provide Composition A having a polymer to compound weight ratio of 35:65. A second melt-processable polymer component consisting of (1) polypropylene (available as DS 5D45 from Union Carbide) with a melt flow index of 0.65 dg/min (ASTM D1238-90b, Condition I) and (2) ethylene-hexene copolymer (available from Exxon Chemicals under the trade designation SLP 9057) with a melt flow index 1.2 dg/min (ASTM D1238-90b, Condition E) was dry blended in a weight ratio of 30:70 and fed into the hopper of a 25 mm twin-screw extruder. Mineral oil was introduced into the 25 mm extruder to provide Composition B having the same polymer to compound weight ratio of 35:65. A nucleating agent (Millad™ 3905 available from Miliken) in the amount of 0.1 parts per 100 parts Composition B was also added. The overall feed rate in the first extruder was 13.6 kg/hr and in the second was 6.8 kg/hr. In each extruder the polymer component was heated to 266° C. to melt it and the temperature was maintained at 204° C. during the extrusion after the polymer component was mixed with the blending compound. The melt streams from both extruders were combined in a triple manifold die to form a layer of Composition A sandwiched between two layers of Composition B. The three layer film was cast onto a casting wheel maintained at 77° C. and having a patterned surface with an inverted pyramid shape that provided about 40% contact area with a cast film. The cast film was oriented 6.5 to 1 in the machine direction at 82° C., then 4 to 1 in the cross direction at 82° C. The oriented film was then continuously washed in dichlorotrifluoroethane.
The resulting film was tested for thickness, Gurley air flow and puncture resistance. Thickness was 20 μm, Gurley was 510 sec/10 cc and puncture resistance was 454 g/25 μm.
Example 4
A microporous film was made to illustrate the effect of a different quenching method.
The microporous film of Example 4 was made in a manner similar to that of Example 2 except the polymer component was different and some equipment and processing conditions were changed. The melt-processable polymer component was DS5D45 polypropylene. Thc flow rates were adjusted to obtain a weight ratio of polymer component to blending compound of 35:65. A nucleating agent (Millad™ 3905) in the amount of 0.09 parts per 100 parts composition was also added to the extruder. The die was 24.1 mm wide and a water bath maintained at 16° C. was used to quench the cast film instead of a chill roll. The overall feed rate was 22.7 kg/hr, the extruder was heated to 266° C. to melt the polymer component and maintained at 188° C. while the components were mixed. The machine direction orientation was 5×1 at 121° C. and the cross-web orientation was 4.7×1 at 121° C.
The film was tested for thickness, Gurley air flow, puncture resistance, porosity and tensile strength at break (MD/CD). Thickness was 13 μm, Gurley was 247 sec/10 cc, puncture resistance was 635 g/25 μm, porosity was 45% and tensile strength at break in the machine and cross-web directions was 882 and 622 kg/cm 2 respectively.
Example 5
A microporous film was made to illustrate the effect of a different type of polymer component and blending compound on film properties.
The microporous film of Example 5 was made in a manner similar to that of Example 1 except some materials and equipment were different and the process conditions were changed. The polymer component was composed of a 30:70 by weight blend of two melt processable polymers, polypropylene (DS5D45) and ethylene-hexene copolymer (available under the trade name of SLP 9057 from Exxon Chemicals Co.) with a melt flow index 1.2 dg/min (ASTM D1238-90B, Condition E). The flow rates were adjusted to obtain a weight ratio of polymer component to blending compound of 40:60. A nucleating agent (Millad™ 3905) in the amount of 0.1 parts per 100 parts composition also was added to the extruder. The die was 20.3 mm wide and the chill roll had a patterned surface with a pyramid shape that provided about 10% contact area with the cast film. The overall feed rate was 4.5 kg/hr, the melting temperature was 271° C., the mixing temperature was 193° C., the chill roll temperature was 65° C. and the stretch conditions were 7×7 simultaneously at 90° C.
The resulting film was tested for thickness, Gurley air flow and puncture resistance. Thickness was 11 μm, Gurley was 802 sec/10 cc and puncture resistance was 687 g/25 μm.
Example 6
A microporous film was made to illustrate the effect of another polymer and blending compound type on film properties.
The microporous film of Example 6 was made in a manner similar to that of Example 5 except some materials were different and the process conditions were changed. The normally melt processable polymer component was linear low density polyethylene (available under the trade designation Dowlex™ 2038) with a melt flow index of 1.0 dg/min (ASTM D1238-90b, Condition I) and no nucleating agent was used. The film was stretched while at a temperature of 110° C.
The resulting film was tested for thickness, Gurley air flow and puncture resistance. Thickness was 10 μm, Gurley was 425 sec/10 cc and puncture resistance was 435 g/25 μm.
Example 7
A microporous film was made to illustrate a liquid/liquid phase separation mechanism.
The microporous film of Example 7 was made in a manner similar to that of Example 5 except some materials were different and the process conditions were changed. The polymer component was composed of a 60:40 by weight blend of two melt processable polymers, polypropylene (DS5D45) and ethylene-hexene copolymer (SLP 9057). The compatible liquid was composed of a 70:30 by weight mixture of mineral oil and PEG 400 dilaurate. The flow rates were adjusted to obtain a weight ratio of polymer component to compatible liquid of 30:70. The film was stretched 5 by 5 simultaneously while at a temperature of 90° C. and washed under restraint in dichlorotrifluoroethane and dried.
The resulting film was tested for thickness, Gurley air flow and puncture resistance. Thickness was 8 μm, Gurley was 218 sec/10 cc and puncture resistance was 473 g/25 μm.
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Briefly, in one aspect, the present invention provides puncture resistant microporous materials made of melt-processable semi-crystalline thermoplastic polymers. The microporous materials can be produced at relatively high rates and at low cost. Films and multilayer constructions made of the microporous materials and methods of making microporous materials also are provided.
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BACKGROUND OF THE INVENTION
Data storage devices have methods to ensure the integrity of the data. In one method, called “read-after-write,” data is put onto the media, and is then immediately read to ensure that the data was correctly written. There is also a process that separately and non-automatically looks at the media and checks to see that it can be read back from the device. This disc verification is a utility (called ScanDisk) that can be used on current PCs.
The mechanism of read-after-write is disadvantageous in a slow device in that it takes a significant amount of extra time to run that process. For example, a CD has a much slower read and write speed than does a hard drive. The data rates for a CD for writing are something today between 300 and 600 Kbytes per second, and a hard drive is on the order of ten times faster than that. The reading speed of a CD is about six times faster than the writing speed, and a hard drive reading speed is the same as the writing speed. Thus, if the user needs to conduct an operation on a CD where data is written and read back, it will be significantly slower than if the user were able to simply write the data to the disc without verifying it. This is how the file system for CD currently works. Data is written but not verified.
When the user does a format operation to prepare a CD disc for taking data, the system typically writes to that disc to arrange where the data will ultimately be put and then verifies that the data is able to be read back. But after the data has been written, the user has no assurance that something hasn't happened to damage the disc between the time of format and the time of writing data. Any rewritable particular media will be used over a long period of time, and many things can happen to that disc. The disc can be scratched, get fingerprints and dirt on it, etc.—All of these factors will affect both the successful writing of additional data as well as reading of the data.
On a hard disk, the media is in a very controlled, sealed environment. You cannot put a fingerprint on a hard disk. You cannot get dirt on a hard disk. But a removable media is exposed to the environment, thereby making it more vulnerable to damage. CD media is particularly susceptible to this damage because it is the only rewritable media that does not have a protective case (i.e. audio tapes, VCR tapes, floppy disks, etc.) When a user does the formatting and verifying, the disc is physically secure since it is in a device away from fingers, etc. But when the CD is removed from the drive problems arise. This is a significant difference between hard disk and CD technology.
All data storage devices take advantage of error correction designed in the format. There are many error correction algorithms. They are all effective in correcting errors and defects, but every method has limitations. A thick thumb print on a CD disc, for instance, will render sections of the CD disc unreadable. Since this type of reusable media is in a very unprotected environment, it will be handled and is likely to become soiled and damaged at random times over a long period of time. Therefore, a method is needed to ensure the steadfastness of data integrity.
SUMMARY OF THE INVENTION
These and other objects, features and technical advantages are achieved by an improved system and method which automatically performs disc verification on the disc without any user intervention. It would run at appropriate intervals, determined by looking at certain parameters of the disc, in order to insure a minimum risk of either data unreadability or data being written on a location unsuccessfully. The improved system includes the error correction processes that currently apply to CD's, but the algorithms will look at the disc and the usage of the disc, in particular, how much the disc has been handled by a user. It will then determine the appropriate time to automatically run the disc verification function and repair of the disc.
One of the features of the error correction on a CD as compared to a hard disk, is that a hard disk will only tell the user whether the data is good or bad. Either the ECC worked or it did not work to correct the data. CD technology typically set a threshold on how much ECC is used before informing the system to relocate the data because of risk of lost data. CD technology also typically allows for the system to inquire how much ECC was used to read the data. The improved system uses this method of inquiring how much ECC was used to intelligently determine if disc verification is required.
Since the process of assessing, cleaning up the disc, and relocating data is done in the background, this system achieves additional protection without having to do a read back after the write process. Consequently, the improved system gains the performance of a write-it-and-go-on device, while preserving the protection of being able to check the disc at regular and appropriate intervals.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a diagram of the operation of the trigger event recording; and
FIG. 2 is a diagram of the operation of error checking as a function of set trigger limits being exceeded.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to FIG. 1, box 101 which advantageously runs on a host processor, such as a PC, or other computing device, monitors the trigger events which occur. The definitions of the trigger events to be monitored are stored on the portable storage medium, (or on the host computer or on a network). Box 102 contains and controls the triggers, which by way of example could be number of media inserts; number of hours of use; number of files that have changed; number of errors or type of errors per hour of use; change in the sparing table; or the differences in the files date and time stamps.
One trigger could be a specified number of times that the media has been inserted into the drive unit of the host processor (not shown). The number of insertions is an indication that someone had to handle it at least x number of times because every time it is inserted it is by a handling process. You don't really know how many other times it has been handled when it is outside the drive so this is a little bit indirect. Each time the disc is inserted in the improved system a counter on the disc would be incremented. When it reached a predetermined value the disc verification process would begin. When completed the counter would be cleared. If data was recovered but took a predetermine amount of ECC the data would be automatically move to a good area on the disc.
A second trigger could be the number of hours of use of the storage media.
The number of hours of use is a further abstraction. The medium could have been sitting inside the drive a long time but the assumption is that after the disc is used so many times it would have been swapped out with other discs. So it is getting at how long the disc has been used and assuming that if it has been used a number of periods of time it would have been removed several times. The system could actually record use on the medium, or on the host. The length of time the disc is in use could be stored on the disc in the improved system. This location would be updated each time the disc was in use. When it reached a predetermined value the disc verification process would begin. When completed this location would be clearer. If data was recovered but took a predetermined amount of ECC the data would be automatically move to a good area on the disc.
A third trigger could be the number of files that have changed. The improved system would watch the number of files that have been written and how many files have been removed. The number of files that have changed (added, modified or deleted) could be stored on the disc in the improved system. This location would be updated each time files changed. When it reached a predetermined value the disc verification process would begin. When completed this location would be cleared. If data was recovered but took a predetermine amount of ECC the data would be automatically move to a good area on the disc.
A fourth trigger is the number and type of errors received. By reading the data the system generates information about how much of the ECC has been involved. That information can be requested along with the data and so the system can set its threshold based on that. In the current CDs there are three levels of error correction. Call them C 1 , C 2 and C 3 . Basically, C 1 and C 2 are combined and you get information about how much of C 1 and C 2 were required to recover the data if there was an error. And then you also get that same information on C 3 . If C 1 and C 2 could not correct it, it will go to C 3 to correct it and the information as to what level of C 3 error correction was required to recover the data is available.
The point is even when you are successful reading the data, you can get some information about how difficult it was and the improved system would utilize the information that is available to make some additional decisions about whether it is appropriate to look for errors on the entire disc.
If the improved system becomes aware that there are a high number of errors occurring during reading, this is an indication that the improved system should look at the entire disc rather than just what the user was reading right then.
The improved system could be set up to readjust the portions that have data or the entire disc. This is important since it increases the likelihood of errors at any location. Running the disc verification routine will allow for the detection of trouble conditions before a user ever tries to write to that area.
If the improved system determines that there are significant portions of bad areas on the disc, it could alert the user that it is time to copy to another disc. Another feature of the improved system is that it will detect contamination and could inform the user to clean the disc before trouble occurs.
The fifth trigger is a change in the sparing table. The sparing table is where the storage device records the places that cannot be written to. The system watches that table and as more locations are added to that table the system knows that the disc is wearing out or that there is additional dirt on the disc. The file system writes that table. So the computer and device as it exists today manage the media and as they are unsuccessful in reading something back or get high error rates they will be relocating data, so our method watches that sparing table and determines when its time to look again at the whole disc.
A fifth trigger could be to determine the difference in data and time between the newest file and the oldest file. This time delta would be saved on the disc. When the delta reaches a predetermined value the disc verification process would begin. When completed this value would be marked as verified. A new time delta would be started from the time delta marked as verified. When this new delta reached a predetermined value the disc verification process would begin. This new time delta would then be stored where the old time delta was and would be marked as verified. If data was recovered but took a predetermine amount of ECC the data would be automatically move to a good area on the disc.
This method is similar to trigger numbers two and three. It has the advantage that continuous monitoring of the files on the disc is not required. It has the disadvantage that only one file of significant time delay could trigger the disc verification process.
Box 103 checks for trigger events and simply logs the various events into table 104 . Some trigger events, however, need not be captured in a table since they are in tables already and that table acts as a trigger such that when that table gets too full (for example, the error table) the system reacts.
FIG. 2 shows the control of the algorithm that determines when to initiate a disc verification process automatically. The user will not have to invoke this procedure. Most users do not have the kind of knowledge to know that they should run a disc verification and thus a key point is to put the intelligence into the system to determine when a disc verification should be run. Even a very experienced user would not necessarily know when this should be done, because if the user had a CD for some time and then handed it to a friend, that friend would not know the state of that disc, nor how much it had been handled, nor how long it had been since it had been cleaned up, etc. Additionally, the friend's device may perform differently with the disc. It may read with more or less errors do to better or worse optics. Using this improved system, a portable memory can have multiple users and multiple owners and still be cared for properly.
Box 201 compares the trigger events table against each individual trigger event set limit box 202 to determine if the set limit has been reached. If it has been reached diagnosis are run, box 205 , which diagnosing could be a disc verification routine, or could be particular to a given type of trigger, if desired. Note also that the trigger limits can be adjusted, as desired, either by a user, or by the system or from information obtained externally, such as from a network/web.
Box 206 reads the medium and box 207 detects and stores errors, or invokes the error table and blocks certain portions of the medium from further use in cooperation with box 208 . In some situations, the trigger event table is updated. Box 205 controls whatever action, such as notifying a user, changing speeds of the system, etc., as appropriate, given the error condition.
There is actually a whole series of protocols that can be used around this concept. One is that nothing is done until the system reaches a certain threshold, for example the error table is 50% full. There could be a nonlinear progression so that as it gets more full disc verification is run more often. Another could be the rate of change you are using the disc and nothing is happening in that table. All of a sudden the system starts to see the table fill up rapidly. The improved system could implement disc verification more often as the rate of that table fills up.
The trigger event list as well as the trigger event occurrence list can be stored on the CD disc, on a public medium or on a host processor. The host processor could transfer one or both of these lists to the portable device at certain times, periodically, or upon certain events, such as the removal of the device from that host, or upon a command from the user.
The improved system described is primarily designed for CD's running in conjunction with a PC or host processor. However, any system using a portable data storage medium can take advantage of the concepts taught herein. For example, DVD's and other storage devices can be scanned to know when their useful life is compromised, or to know when to move data to an alternate storage location before that data is lost forever. In some situations, even the hard drive of the processor can be mainframed in this fashion.
Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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A system and method for determining when data stored in a data storage device is becoming unreliable. A list of trigger events is maintained, either on the media, or on a host processor, and the number of trigger events pertaining to data retrieval errors is also maintained either on the disc media or on the host processor. Based upon the trigger events and the running totals, the disc media is scanned for errors from time to time and the error detecting algorithm can change depending upon the respective trigger totals. The triggers are typically representative of events likely to cause errors to occur and can be tailored to different types of storage media
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RELATED APPLICATIONS
[0001] This application claims the benefit of the U.S. provisional patent application “Failure Analysis Using Design Rules” Ser. No. 61/299,952, filed Jan. 30, 2010. The foregoing application is hereby incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] This application relates generally to semiconductor failure analysis and more particularly to failure analysis using design rules.
BACKGROUND
[0003] Semiconductor chips are vastly complex structures. There are numerous metal lines of miniscule dimension in close proximity to one another. There are diffusions, polysilicon shapes, and insulator layers, all of which need to be fabricated to exacting tolerances. An error in any step of fabrication or the presence of even the smallest defect can cause a failure in the operation of a chip. Failures on semiconductor chips may be the result of random defects or systematic defects on the chips. Design problems with semiconductor devices are traditionally overcome by having layout design rule checks (DRCs) evaluated against a chip layout prior to beginning mask and chip fabrication. With the advent of deep sub-micron technologies, new fault models are being detected which cannot be covered by traditional design rule checking processes.
[0004] There remains a need for an improved failure analysis process.
SUMMARY
[0005] Through the use of design rule checks, improved failure analysis of semiconductor chips can be accomplished. A user of a failure analysis tool may take an existing layout database and search the layout for electrical signals which have a suspect relationship with other signals or the surrounding layout shapes. Rules may be defined which can be executed to confirm complex failure models or to find areas of interest defined by complex geometrical constraints. Layout and netlists may each be displayed to aid in failure analysis.
[0006] A computer implemented method is disclosed for performing semiconductor failure analysis comprising: importing a semiconductor layout; having a set of rules wherein each rule of the set of rules describes a design rule check for the semiconductor layout; selecting a rule from the set of rules to apply to the semiconductor layout; identifying a portion of the semiconductor layout by searching through the semiconductor layout for a match to the rule which was selected; and displaying the portion of the semiconductor layout. The method may include importing a netlist corresponding to the semiconductor layout. The method may include performing electrical analysis on the netlist. The method may include storing results of the electrical analysis. The method may include displaying waveforms from the electrical analysis. The method may include storing an image of the portion of the semiconductor layout. The method may include importing defect information from a semiconductor fabrication process. The identifying may be accomplished by progressively searching through the semiconductor layout to find a match between the rule and a subset of the semiconductor layout. The rule may describe a two-dimensional Boolean operation on shapes of a layer. The rule may describe a two-dimensional Boolean operation on shapes of a plurality of layers. The rule may describe a two-dimensional Boolean operation on shapes of one or more layers as well as neighboring electrical traces identified from the electrical analysis of the netlist. The rule may describe a two-dimensional Boolean operation on shapes of one or more layers as well as shapes of waveforms resulting from the electrical analysis. The rule may describe a two-dimensional Boolean operation on shapes of one or more layers and shapes of potential defects derived from one of defect scanning tools and yield management systems. The rule may describe one or more of sizing constraints and spacing constraints. The rule may describe shape-oriented operations. The rule may be used to describe a potential defect which is systematic. The method may include providing CAD navigation to the portion of the semiconductor layout. The method may include moving a probing location on a chip to the portion of the semiconductor layout. The set of rules may be created as part of the semiconductor failure analysis. The set of rules may be imported. The set of rules may be defined within an electronic design automation tool.
[0007] In some embodiments, a computer program product may be embodied in a non-transitory computer readable medium that, when executed on one or more processors, analyzes semiconductor failures by performing steps of: importing a semiconductor layout; having a set of rules wherein each rule of the set of rules describes a design rule check for the semiconductor layout; selecting a rule from the set of rules to apply to the semiconductor layout; identifying a portion of the semiconductor layout by searching through the semiconductor layout for a match to the rule which was selected; and displaying the portion of the semiconductor layout. In some embodiments, a system for performing semiconductor failure analysis may comprise: a memory for storing instructions; one or more processors attached to the memory wherein the one or more processors are configured to: import a semiconductor layout; have a set of rules wherein each rule of the set of rules describes a design rule check for the semiconductor layout; select a rule from the set of rules to apply to the semiconductor layout; and identify a portion of the semiconductor layout by searching through the semiconductor layout for a match to the rule which was selected; and a display to present the portion of the semiconductor layout.
[0008] Other aspects, features, and advantages will be apparent from the following detailed description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The following detailed description of certain embodiments thereof will be understood by reference to the following figures wherein:
[0010] FIG. 1 is a flowchart for performing semiconductor failure analysis using design rule checks.
[0011] FIG. 2 is an example diagram of a layout portion on which design rule checks can be performed.
[0012] FIG. 3 is a diagram of a system for performing semiconductor failure analysis using design rule checks.
[0013] FIG. 4 is a diagram of a failure analysis system with a design rule check engine.
[0014] FIG. 5 is a flowchart for design rule check creation.
[0015] FIG. 6 is a flowchart for design rule check execution.
DETAILED DESCRIPTION
[0016] The present disclosure provides a description of various methods and systems associated with performing semiconductor failure analysis using design rule checks (DRCs). Failure analysis can include evaluation of failing semiconductor devices to determine root cause of failure through examination of the structures and defects on a physical device. Design rule checking can include evaluating semiconductor layout structures for specific patterns where the patterns and key dimensions are defined as rules. Users may create rules to search on specific geometric relationships within semiconductor layout shapes based on electrical signals and possible defect locations. Rules may describe one or more of sizing constraints and spacing constraints. Rules may describe shape-oriented operations.
[0017] As semiconductor technologies advance they tend to rely on ever-smaller geometries. Unfortunately, as the geometries become smaller systematic defects in semiconductors tend become increasingly difficult to track down and remedy.
[0018] A variety of systematic defects are possible. For example, a systematic defect can be due to polygon design within a layout or due to fabrication where adjacent shapes are regularly produced in an incorrect fashion; a systematic defect may be produced by process and design interactions; and so on. Other systematic defects will be appreciated.
[0019] In practice, systematic defects can be subtle and tracking them down can require careful testing. It is therefore desirable to be able to identify systematic defects during failure analysis. In some cases, a systematic defect may only be detectable with a certain arrangement of shapes, such as a group of polygons (or constellation) in the layout. Furthermore, certain arrangements of polygons may be more susceptible to defects and require careful failure analysis based on the layout using.
[0020] Traditional design rule checking performs design verification using “pre-silicon” shapes. The pre-silicon shapes are design shapes that may or may not reflect the ultimate fabricated shapes. The fabricated shapes can have foreshortening, rounding, and other modifications that are a function of light waves and the limits of physics and chemistry at the small dimensions on the semiconductor chip.
[0021] This application describes a failure analysis technique that analyzes semiconductor layouts using DRCs. An example design rule check (DRC) for one type of systematic defect can include evaluating two adjacent tracks to ensure that they are not closer than a certain specified value. In embodiments, a design rule may be created to identify a certain arrangement of polygons and then checked against the remainder of the semiconductor layout to identify other defect sensitive sites. The design rule may be used to describe a potential defect that is systematic. A variety of design rules will be appreciated.
[0022] Some embodiments of the failure analysis design rule checking described in this application include analysis with the pre-silicon shapes. Some embodiments include the pre-silicon shapes along with “post-fabrication” shapes reflecting the shape modifications that occur during fabrication.
[0023] In some embodiments defects may modify shapes or hot-spots identified with the shapes being modified accordingly. In some embodiments, these post-fabrication shapes may be used in preventive analysis prior to fabrication while the design may still be modified.
[0024] FIG. 1 is a flowchart for performing semiconductor failure analysis using design rule checks. A failure analysis process 100 begins with importing the semiconductor layout 110 . The layout may be in the form of GDSII or Oasis or some other format for describing various shapes, sizes, and relationships of elements in a semiconductor layout. The layout may be for a semiconductor chip or die. The layout may be imported into a database to be included with other information about the chip.
[0025] Rules are received 115 , the rules describing design rule checks for manufacturing technology in which a chip is to be fabricated. The rules may include rules describing a design rule check for the layout. In some embodiments, a foundry in which the chip is to be fabricated may provide the rules. In some embodiments, the rules may be generated as part of the failure analysis process 100 . The rules may describe widths of certain structures on chip, spacings between structures, overlap between one shape and another shape, or any other checks that may help in verifying the layout.
[0026] One or more of the rules are selected 120 . This may include selecting a rule to apply to the layout. The rule may be selected in an automated fashion or may be specifically chosen by a user to perform a specific failure analysis. In some embodiments, a rule may be recommended by a foundry as pertinent to failure analysis due to, for example, recent fabrication experience, returns from the field where a number of failures were encountered, and so on.
[0027] A netlist may be imported 122 . The netlist may correspond to the layout. The netlist may describe electrical components that make up the chip. The components may include inverter, AND, OR, NAND, NOR, XOR, XNOR, MUX, and other types of logical gates. The components may include multipliers, adders, ALUs, processors, cores, and other portions of logic. The netlist may include a description of interconnections between the various components as well as individual transistors. The netlist may further include information on the components including size, delay, power, and other characteristics.
[0028] An electrical analysis may be performed on the netlist 124 . The electrical analysis may include determining electrical connectivity, delay, power, timings, or other aspects related to the operation of the semiconductor chip. In embodiments, electrical analysis may include analyzing the relationship of electrical signals to each other or to surrounding passive structures. The analysis may allow failure analysis personnel to access the layout and search within an area of interest for special geometric relationships between shapes on various layers. The failure analysis process 100 may include online searches of a layout database for geometric features defined by a set of rules. The impact of defects from a manufacturing process on electrical signals may be analyzed along with the impact on operation. In some embodiments, importing the netlist 122 or performing electrical analysis 124 can be omitted without diverging from the scope of this disclosure. It will be appreciated that the process 100 may include storing the results of the electrical analysis, displaying waveforms from the electrical analysis, and so on.
[0029] A portion of the layout is identified by searching through the semiconductor layout for a match to the rule that was selected 130 . The portion of the layout may be identified based on the layout itself along with the rule that was selected. In some embodiments, the portion of the layout is identified based on the layout, the electrical analysis, the rule that was selected, and so on.
[0030] The portion of the layout may be identified by searching through the whole layout for a match to the DRC corresponding to the rule that was selected. In some embodiments, a section of the layout is used as a starting point for searching for a match to the rule that was selected. The section may be chosen based on a history of failures or some other focused concern. There may be failures in a specific group of components or portion of a semiconductor chip where a selected rule may be applied against that section of the layout. The identifying may be accomplished by progressively searching through the semiconductor layout to find a match between the rule and a subset of the semiconductor layout. The subset may include the entire chip or any portion of the chip.
[0031] The design rule checking may describe a two-dimensional Boolean operation on shapes of a layer. Two-dimensional Boolean checking may be a combination of two or more rules to filter out and find a desired shape, area, or polygon in the layout.
[0032] Two-dimensional Boolean checking may allow for creating complex search criteria based on different parameters. For example, two-dimensional Boolean checking may allow for finding a particular polygon or pattern by using two rules. One rule may be for filtering polygons that meet a certain width criteria. A second rule may check for overlap to narrow the search results to the desired criteria.
[0033] A search may alternatively be based on two-dimensional Boolean operations on shapes on differing layers. A search may be based on two-dimensional Boolean operations on shapes on one or more layers and based on the shapes of certain electrical signal wires. A search may be based on two-dimensional Boolean operations on shapes on one or more layers and based on defect shapes derived from defect scanning tools. Defect shapes may also be derived from yield management systems. Searching may be based on size or spacing constraints. Searching may be based on shape-oriented operations.
[0034] A two-dimensional Boolean operation may include accomplishing two rule checks as part of a search. For example, two rule checks might include a check for a metal width and a check for a metal extension beyond a via. For another example, two rule checks might include a polysilicon width and an extension of the polysilicon shape past the end of a diffusion.
[0035] A rule may describe a two-dimensional Boolean operation on shapes of a plurality of layers. A rule may describe a two-dimensional Boolean operation on shapes of one or more layers as well as neighboring electrical traces identified from the electrical analysis of the netlist. A rule may describe a two-dimensional Boolean operation on shapes of one or more layers as well as shapes of waveforms resulting from the electrical analysis. A rule may describe a two-dimensional Boolean operation on shapes of one or more layers and shapes of potential defects derived from one of defect scanning tools and yield management systems.
[0036] Defect information may be imported from a semiconductor fabrication process 126 . The defect information may include the size, the type, the level in the fabrication process at which a defect appears, and other aspects about the defect. The defect information may be obtained from the foundry, a third party analyst, or the like. Further, the defect information may be based on experience with previous technologies and so on. In some embodiments a portion of the layout may be identified based on a rule that is selected 120 and based on the defect information that was imported 126 .
[0037] A portion of the semiconductor layout may be displayed 140 . It will be appreciated that a variety of graphical user interface techniques (e.g., highlighting, color emphasis, zoom, etc.) can be applied to the portion of the layout as displayed. It will be further appreciated that the any and all of the portion of the layout as displayed can be stored to a computer-readable medium.
[0038] Computer Aided Design (CAD) navigation to the portion of the layout as displayed may be provided 150 . The CAD navigation may involve movement of a wafer or a test head so that analysis is done at a desired location on the semiconductor device. The CAD navigation may be used with a piece of test equipment where a wafer or chip is moved to a location where the layout that was identified is observed under a microscope.
[0039] The semiconductor chip may be probed 160 , for example, by moving a probing location on a chip to the portion of the semiconductor layout. Based on the layout portion which was identified a possible defect site may be determined. A tester may use CAD navigation to move the tester to the portion of the layout that was identified. The portion of the layout may be probed by electrical probing with metal connectors, electron beam probing, laser probing, or other type of probing.
[0040] FIG. 2 is an example diagram of a layout portion on which design rule checks can be performed. In this exemplary diagram metal line 210 has a via 220 which provides electrical connection to the next layer of metal line. The via 220 may be required to have a width 225 and be verified by a DRC. An example via width is 100 nm. The metal line 210 may be required to have an extension 235 of a specified value and may be verified by a DRC. An example extension is 10 nm. Numerous other types of DRCs exist including diffusion-to-diffusion spacings, contact areas, minimum metal-to-metal spacings, dog-bone end sizing requirements on polysilicon shapes, via adjacency requirements, and so forth. Numerous DRCs may be used to aid failure analysis.
[0041] FIG. 3 is a diagram of a system 300 for performing semiconductor failure analysis using design rule checks. One or more processors 310 may communicate with memory 320 . The memory 320 may store data on the layout, rules, netlist, and other aspects of the semiconductor. The memory 320 may store instructions for performing the failure analysis, for displaying information on defects, for operating tester equipment, and so on. The processor 310 may render information on a display 330 . The display may be used to show the layout and images of the semiconductor chip along with defect information and other information for performing failure analysis.
[0042] The processor 310 may read in layout information 340 about the semiconductor chip. The layout information 340 may include design dimensions and associated shapes. The layout information 340 may include modified shapes to aid in fabrication such as optical proximity correction (OPC) shapes. The layout information 340 may include information on post-fabrication shapes. Other layout information will be appreciated for various purposes.
[0043] The processor 310 may read in rules 342 such as design rule checks used to aid in failure analysis. The rules 342 may help to identify regions of layout that may be of concern for random defects or for systematic defects. The processor 310 may analyze the layout 340 in light of the rules 342 to identify layout portions for further failure analysis.
[0044] The processor 310 may read in netlist information 344 about the semiconductor chip. The netlist 344 may be used with the layout 340 along with the rules 342 to identify portions of the chip for failure analysis.
[0045] The processor may interact with the test equipment and prober 350 . The test equipment 350 may include an optical or scanning electron microscope, a wafer or chip stage, electrical stimulus and power supply capability, and electrical or contactless probing apparatus. The test equipment 350 may move over wafer 360 via CAD navigation. The test equipment 350 may probe the wafer 360 or a chip at the correct point to perform failure analysis and identify a defect.
[0046] FIG. 4 is a diagram of a failure analysis system with a design rule check engine. The failure analysis system 400 includes a user interface 410 , a rule generator 420 , a search tool 430 , and a DRC engine 440 . Within the rule generator 420 , templates 424 may reside which can be used to define rules that are desired by a user during failure analysis. The rule generator 420 may use one or more templates 424 in a definition tool 422 . The definition tool 422 may provide rules to the user interface 410 . A template may filter and identify certain layers or certain dimensions of concern. Rules may be generated during the failure analysis process that match certain templates. A set of rules may be created as part of the semiconductor failure analysis. In some embodiments, the rules may be imported or may be provided by a foundry, an analysis party, or some other third party.
[0047] The user interface 410 may include a dialog box, a viewer 414 , and a virtual layer editor 416 . A dialog box 412 may allow reading in of various rules. The dialog box 412 may also prompt the user to provide information and create rules for failure analysis using the rule generator 420 . The dialog box 412 may be used to select one or more rules for use in analysis of a layout. The dialog box 412 may capture commands that are fed to the search tool 430 .
[0048] The search tool 450 allows for searching across a semiconductor layout using one or more rules. The search tool 430 uses a DRC engine 440 to exercise the rules that were selected in the dialog box 412 to search through the layout. The search tool 430 finds matches in the layout with the selected rules.
[0049] A virtual layer editor 416 captures the portion of the layout that was identified by the search tool 430 . The virtual layer editor 416 may be used to exchange information about features in the layout. The virtual layer editor 416 may add layers to the layout. These added layers do not reflect any physical design shapes but are instead virtual layers that can help identify areas of concern to designers and failure analysis engineers. The virtual layers can be used to draw geometric shapes, add text, or incorporate lines to annotate the layout. Among other items that may be incorporated are locations for focused ion beam modifications such as probe points, added signal wires, or metallization removal areas. The layout portion where the virtual layers are added may be displayed through the viewer 414 . Data from the viewer 414 may be fed back to the search tool 430 to refine the search. The viewer 414 provides location and other information into the dialog box 412 . The dialog box 412 can capture instructions to modify the search parameters or move locations on the semiconductor device for further searching by the search tool 430 .
[0050] FIG. 5 is a flowchart for design rule check creation. The process 500 begins with identifying one or more variables 510 . The variables relate to the layers for which the rule is being created. The variables may include information on widths, spacings, shapes, and other aspects of a possible rule.
[0051] A rule is created 520 . The rule may include a specific dimension for a width of a shape. The rule may include a dimension for a space between shapes. The shapes may be on the same or different levels. A rule may identify one or more layers. A rule may identify layout shapes for which to search. In some embodiments, rules identify certain electrical structures and their associated layout shapes for which to search. The rules may have been imported or may have been created by the failure analysis software. The rules may have been obtained from a foundry, from a fabrication analysis team, or from experience based on previous failure analysis and manufacturing defects. The rule is saved 530 for future use or documentation purposes.
[0052] FIG. 6 is a flowchart for design rule check execution. The process 600 begins with initiation of the CAD software 610 . This software may be used for CAD purposes, for failure analysis purposes, or be part of some larger electronic design automation (EDA) package. Initiating the software may include opening or loading the semiconductor layout.
[0053] The rule is selected 620 . The rule may identify one or more layers. The rule may identify layout shapes for which to search. The rule may identify certain electrical structures and their associated layout shapes to search. The rule may have been imported or may have been created by the failure analysis software. The rule may have been obtained from a foundry, from a fabrication analysis team, or from experience based on previous failure analysis and manufacturing defects.
[0054] Run time information is obtained 630 . The run time information may include instructions on the specific processors on which to execute.
[0055] The rule is executed against the semiconductor layout 640 . The rule may be used to search for a portion of the layout that matches the rule. This portion of the layout may be displayed on a layout editor or viewing tool.
[0056] Each of the above methods may be executed on one or more processors on one or more computer systems. Embodiments may include various forms of distributed computing and client/server computing. Further, it will be understood that for each flow chart in this disclosure, the depicted steps or boxes are provided for purposes of illustration and explanation only. The steps may be modified, omitted, or re-ordered and other steps may be added without departing from the scope of this disclosure. Further, each step may contain one or more sub-steps. While the foregoing drawings and description set forth functional aspects of the disclosed systems, no particular arrangement of software and/or hardware for implementing these functional aspects should be inferred from these descriptions unless explicitly stated or otherwise clear from the context. All such arrangements of software and/or hardware are intended to fall within the scope of this disclosure.
[0057] The block diagrams and flowchart illustrations depict methods, apparatus, systems, and computer program products. Each element of the block diagrams and flowchart illustrations, as well as each respective combination of elements in the block diagrams and flowchart illustrations, illustrates a function, step or group of steps of the methods, apparatus, systems, computer program products and/or computer-implemented methods. Any and all such functions may be implemented by computer program instructions, by special-purpose hardware-based computer systems, by combinations of special purpose hardware and computer instructions, by combinations of general purpose hardware and computer instructions, by a computer system, and so on. Any and all of which may be generally referred to herein as a “circuit,” “module,” or “system.”
[0058] A programmable apparatus which executes any of the above mentioned computer program products or computer implemented methods may include one or more processors, microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors, programmable devices, programmable gate arrays, programmable array logic, memory devices, application specific integrated circuits, or the like. Each may be suitably employed or configured to process computer program instructions, execute computer logic, store computer data, and so on.
[0059] It will be understood that a computer may include a computer program product from a computer-readable storage medium and that this medium may be internal or external, removable and replaceable, or fixed. In addition, a computer may include a Basic Input/Output System (BIOS), firmware, an operating system, a database, or the like that may include, interface with, or support the software and hardware described herein.
[0060] Embodiments of the present invention are not limited to applications involving conventional computer programs or programmable apparatus that run them. It is contemplated, for example, that embodiments of the presently claimed invention could include an optical computer, quantum computer, analog computer, or the like. A computer program may be loaded onto a computer to produce a particular machine that may perform any and all of the depicted functions. This particular machine provides a means for carrying out any and all of the depicted functions.
[0061] Any combination of one or more computer readable media may be utilized. The computer readable medium may be a non-transitory computer readable medium for storage. A computer readable storage medium may be electronic, magnetic, optical, electromagnetic, infrared, semiconductor, or any suitable combination of the foregoing. Further computer readable storage medium examples may include an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM), Flash, MRAM, FeRAM, phase change memory, an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
[0062] It will be appreciated that computer program instructions may include computer executable code. A variety of languages for expressing computer program instructions may include without limitation C, C++, Java, JavaScript™, ActionScript™, assembly language, Lisp, Perl, Tcl, hardware description languages, database programming languages, functional programming languages, imperative programming languages, and so on. In embodiments, computer program instructions may be stored, compiled, or interpreted to run on a computer, a programmable data processing apparatus, a heterogeneous combination of processors or processor architectures, and so on. Without limitation, embodiments of the present invention may take the form of web-based computer software, which includes client/server software, software-as-a-service, peer-to-peer software, or the like.
[0063] In embodiments, a computer may enable execution of computer program instructions including multiple programs or threads. The multiple programs or threads may be processed more or less simultaneously to enhance utilization of the processor and to facilitate substantially simultaneous functions. By way of implementation, any and all methods, program codes, program instructions, and the like described herein may be implemented in one or more thread. Each thread may spawn other threads, which may themselves have priorities associated with them. In some embodiments, a computer may process these threads based on priority or other order.
[0064] Unless explicitly stated or otherwise clear from the context, the verbs “execute” and “process” may be used interchangeably to indicate execute, process, interpret, compile, assemble, link, load, or a combination of the foregoing. Therefore, embodiments that execute or process computer program instructions, computer-executable code, or the like may act upon the instructions or code in any and all of the ways described. Further, the method steps shown are intended to include any suitable method of causing one or more parties or entities to perform the steps. The parties performing a step, or portion of a step, need not be located within a particular geographic location or country boundary. For instance, if an entity located within the United States causes a method step, or portion thereof, to be performed outside of the United States then the method is considered to be performed in the United States by virtue of the entity causing the step to be performed.
[0065] While the invention has been disclosed in connection with preferred embodiments shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is not to be limited by the foregoing examples, but is to be understood in the broadest sense allowable by law.
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The use of design rule checks for failure analysis of semiconductor chips is described. The smaller geometries of recent semiconductor devices lead to a much higher level of sensitivity of devices to photolithography related systematic problems. Failure analysis to date has focused on physical, randomly distributed defects of devices rather than systematic problems caused by the mask manufacturing or mask application process. Methods and systems are described which allow for online searches of a layout database for geometric features defined by a set of rules. The rules may be defined as two-dimensional Boolean operations including shape or distance based as well as any kind of combination. The result is graphically and interactively presented.
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BACKGROUND OF THE INVENTION
TECHNICAL FIELD
A process for forming a photoresist pattern is disclosed. In particular, a process for forming a photoresist pattern is disclosed that comprises the steps of treating an exposed photoresist resin with a basic gas phase compound under conditions sufficient to form a substantially vertical pattern.
DESCRIPTION OF THE BACKGROUND ART
Current methods allow production of 150 nm L/S photoresist patterns using 248 nm wavelength light (e.g., KrF exposer). However, formation of high quality photoresist patterns smaller than 150 nm L/S have been relatively unsuccessful. For example, use of short wavelength light sources, such as ArF (193 nm), F 2 (157 nm), EBW (13 nm), with low transmittance photoresist resins have resulted in poor quality patterns. And photoresist resins that are typically used with i-line (365 nm) and KrF (248 nr) light sources have a relatively high absorbance of 193 nm wavelength light because they typically contain aromatic compounds. Therefore photoresist resins comprising aromatic compounds are not suitable to use with ArF light source. Photoresist compositions comprising acrylic or alicyclic resins developed for ArF light source still have a relatively high absorbance of 193 nm wavelength light even though they contain no aromatic compounds. In addition, 157 nm L/S photoresist patterns produced from photoresist resins comprising typical organic compounds are generally of a poor quality because C—H, C═C, C═O bonds and aromatic compounds readily absorb 157 nm wavelength light.
Use of conventional chemically amplified photoresist resins having a low transmittance result in majority of light absorption in the upper portion of the photoresist resin and a significantly lower amount of light reaching the bottom portion of the photoresist resin. Thus, a higher amount of acid is generated in the upper portion of the photoresist resin compared to the lower portion of the photoresist resin. This acid gradient can result in a bulk slope profile pattern as shown in FIG. 1 b.
One method of overcoming some of the above described problems is to use a photoresist resin which has a relatively high transmittance. Using a high transmittance photoresist resin results in a substantially equal amount of light reaching both the upper and bottom portions of the photoresist resin, which allows formation of a desired vertical pattern as shown in FIG. 1 a . While efforts have been made to produce a fine photoresist pattern (i.e., 150 nm L/S or better) using a photoresist resin and light wavelengths of 157 nm (F 2 ) and 13 nm (EUV), these efforts have not been successful thus far.
SUMMARY OF THE DISCLOSURE
A process for forming a substantially vertical photoresist pattern is disclosed even when a highly light absorbing (i.e., low transmittance) photoresist resin is used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a shows a pattern profile obtained using a low light absorbance photoresist resin;
FIG. 1 b shows a pattern profile obtained using a high light absorbance photoresist resin;
FIG. 2 shows a photoresist pattern obtained in Comparative Example 1; and
FIG. 3 shows a photoresist pattern obtained in Invention Example 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A process is disclosed for forming a photoresist pattern by treating a photoresist film with a gas phase basic compound under conditions sufficient to produce a substantially vertical photoresist pattern. Without being bound by any theory, it is believed that the gas phase basic compound neutralizes at least a portion of the acid generated in the upper portion of the photoresist film. This is believed to be particularly useful for photoresist resins having a relatively high light absorbance.
As used herein, the term “treating”, refers to contacting the photoresist film to a gas phase basic compound under substantially controlled conditions to produce the desired photoresist pattern, e.g., a substantially vertical photoresist pattern. For example, contacting the photoresist film to a known concentration of the gas phase basic compound for a predetermined or desired period of time. It should be appreciated that this is significantly different from exposure of the photoresist film to an ambient amine compound which can be present in the atmosphere, because the concentration of ambient amine compound is typically not measured and/or can not be controlled to produce a substantially vertical photoresist pattern.
As used herein, the term “substantially vertical pattern” refers to a photoresist pattern in which the angle from substrate to pattern is 80-90 degrees.
Preferably, the gas phase basic compound is selected from the group consisting of an amine compound, an amide compound, urethane and urea. More preferably, the gas phase basic compound is an amine compound. And most preferably, the gas phase basic compound is ammonia.
Another aspect of the present invention provides a process for forming a photoresist pattern comprises treating a photoresist composition coated substrate, which has been exposed to light using an exposer, with a gas phase basic compound under conditions sufficient to produce a substantially vertical photoresist pattern.
In one particular embodiment a process for forming a photoresist pattern comprises the steps of:
(a) coating a photoresist composition on a substrate to form a coated substrate;
(b) exposing the coated substance to light using an exposer to produce an exposed substrate;
(c) treating the exposed substrate with gas phase basic compound to produce treated substrate; and
(d) developing the treated substrate, wherein the step of treating exposed substrate results in production of a substantially vertical photoresist pattern.
The disclosed process will now be described in reference to an amine basic subsequent description presumes that the basic gas employed is an amine gas.
The disclosed process will be described with regard to using an amine gas phase compound to treat the photoresist film to produce a substantially vertical photoresist pattern. It should be noted that the following description of the disclosed process assists in illustrating various features of the present invention and are provided for the purpose of illustrating the practice of the disclosed process and do not constitute limitations on the scope thereof.
In step (c), the exposed substrate is treated in a gas chamber comprising a gas phase amine compound. The amine concentration in the gas chamber can vary depending on a variety of factors such as temperature and the photoresist composition used. The treatment time can also vary depending on a variety of factors enumerated above as well the concentration of the amine compound in the chamber. Typically, however, the amine concentration in the chamber is from about 1 to about 5 ppb. And a typical treatment time is from about 20 to about 60 seconds.
Without being bound by any theory, it is believed that a low transmittance photoresist resin generates more acid in the upper portion of the photoresist film than in the bottom portion, such a photoresist resin typically results in a sloped photoresist pattern as illustrated in FIG. 1 b . As used herein, the term “low transmittance photoresist resin” refers to a photoresist resin having a high light absorbance in the upper portion of the photoresist film such that only a relatively small amount of light penetrates into the bottom portion of the photoresist film.
It is believed that during the amine treatment, the amine diffuses or penetrates into the photoresist film and neutralizes at least some of the acids in the upper portion of the photoresist film, thus resulting in a more uniform acid concentration throughout the photoresist film depth. For example, during an amine treatment, a large amount of amine compound is initially present in the upper portion of the photoresist film relative to the bottom portion of the photoresist film. It is believed that at least a portion of this amine compound is neutralized by the acids that are generated by photolysis. As a result, there is a gradual decrease in the amount of amine compound diffusing into the lower portion of the photoresist film. This decrease in the amount of amine compound through the depth of the photoresist film results in an amine compound gradient along the depth of the photoresist film which is believed to be responsible for reduction or prevention of the formation of a sloped photoresist pattern.
The disclosed process is useful in forming a substantially vertical fine photoresist pattern from any conventional photoresist composition which comprises a photoacid generator. Typically, the photoresist compositions that are used in the process of the present invention comprises a photoresist resin (i.e., polymer), a photoacid generator and an organic solvent. While the process of the present invention can be used with any conventional photoresist polymers, in one particular embodiment of the present invention, the photoresist resin is poly(tert-butyl bicyclo[2.2.1]hept-5-ene-2-carboxylate/2-hydroxyethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate/bicyclo[2.2.1]hept-5-ene-2-carboxylic acid/maleic anhydride).
The disclosed process can also include heating (i.e., baking) the coated substrate (i.e., before step (b)), treated substrate (i.e., after step (c)), or combinations thereof. Typically, the substrate is heated to temperature of about 100 to about 200° C.
Exemplary light sources (i.e., exposers) which are useful for forming the photoresist pattern include light sources which generate light having wavelength of about 250 nm or below. Preferred light sources include, but are not limited to, ArF (193 nm) exposer, KrF (248 nm) exposer, F 2 (157 nm) exposer, EUV (13 nm) exposer, E-beam, X-ray and ion beam.
Another aspect of the disclosed process provides a semiconductor element manufactured by the process described above.
Additional objects, advantages, and novel features of the disclosed process will become apparent to those skilled in the art upon examination of the following examples thereof, which are not intended to be limiting.
EXAMPLES
Measurement of Transmittance
Photoresist resin DHA1001 (a photoresist composition manufactured by Dong-jin Semichem Inc., Korea) comprising poly(tert-butyl bicyclo[2.2.1]hept-5-ene-2-carboxylate-2-hydroxyethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate/bicyclo[2.2.1]hept-5-ene-2-carboxylic acid/maleic anhydride) was coated on a quartz-wafer. The coated wafer was baked at 150° C. for 90 seconds, and cooled to 23° C. (photoresist thickness: about 0.5 μm). The transmittance of the resulting photoresist resin measured using JASCO VUV 200 spectrometer was 45%.
Comparative Example I
At an environmental amine concentration of 1 ppb, the DHA1001 photoresist composition used in Example I was coated on the wafer at a thickness of about 0.4 μm, baked at 150° C. for 90 seconds, and cooled to 23° C. The coated photoresist was exposed to light using an ArF exposer, baked at 140° C. for 90 seconds, and developed in 2.38 wt % TMAH solution to produce a 140 nm L/S pattern. As shown in FIG. 2, the photoresist pattern was severely sloped. It is believed that this was due to the low transmittance of the photoresist composition.
Invention Example I
At an environmental amine concentration of I ppb, the DKA1001 photoresist composition used in Example I was coated on the wafer at a thickness of about 0.4 μm, baked at 150° C. for 90 seconds, and cooled to 23° C. The coated photoresist was exposed to light using an ArF exposer and treated with a gas phase amine for 30 seconds in an amine chamber at an amine concentration of 3 ppb. The treated water was post-baked at 140° C. for 90 seconds, and developed in 2.38 wt % TMAH solution to produce a 140 nm L/S pattern. As shown in FIG. 3, although the DHA1001 photoresist has a low transmittance, a vertical pattern was formed when the exposed photoresist was treated with a gas phase amine compound.
As the comparison of Comparison Example I and Invention Example I shows, when the exposed photoresist film is treated with a gas phase amine compound, it is believed that the amine compound penetrates into the photoresist film layer, thereby providing an amine gradient within the photoresist film. Accordingly, a proportionally large amount of acid in the upper portion of the photoresist film is neutralized and produces a substantially vertical photoresist pattern even when the photoresist resin has a light low transmittance (i.e., high light absorbance).
The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit this disclosure to the form or forms disclosed herein. Although the description of the disclosed process has included description of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the this disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
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A process for producing a photoresist pattern is disclosed. In particular, the disclosed process for forming a photoresist pattern reduces or prevents poor quality photoresist patterns formation, especially when a high light absorbing (i.e., low transmittance) photoresist resin is used. In one aspect, a photoresist film which has been exposed to light is treated with a gas phase basic compound to produce a substantially vertical photoresist pattern.
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FIELD OF THE INVENTION
This invention relates generally to large space structures, including environmental habitats, and particularly to such structures which are formed in a mold. The mold is prefabricated on Earth, folded and placed in a container for insertion into a space orbit, and then unfolded and formed once in the space orbit. Forming is accomplished by the injection of chemically hardenable materials in the prefabricated, collapsable mold.
BACKGROUND OF THE INVENTION
Presently it is proposed to build large structures in space by partially assembling by welding, bolting, etc., large structural components together and then transporting the partially assembled components into space where the components are to be assembled to complete the space structure. Such approach requires many launchesa, including space trips to insert the components into orbit and space trips to insert the men and tools into orbit with the components to complete the assembly. The device of the present invention utilizes the properties of space for the construction of large structures, including environmental habitats and/or protective shells, etc., without regarding excessive launches and without requiring men to be in orbit for long periods of time to complete the construction. For structures such as habitats, the use of man-hours in space suits are minimized. The internal construction is done in an enclosed space which is inflated by breathable gases to provide an Earth-like environment, with no requirement for space suits.
SUMMARY OF THE INVENTION
In accordance with this invention, the properties of space, specifically, a vacuum environment and no effective gravity for orbiting bodies, are utilized for the construction of environmental habitats, protective shells, and reinforcing structures for such things as equipment and people. The space structure includes a flexible, non-permeable, generally non-elastic mold having a predetermined configuration. The mold is placed in a container in a folded or collapsed state, on Earth, and formed to its predetermined configuration by injection of chemically hardenable materials therein once in orbit. The vacuum condition of space allows the mold, of film and/or sheet and/or fabric, to hold its shape using very low pressure, and the lack of gravity ensures a substantially sag-free mold while the chemically hardened materials are injected ito the mold and allowed to harden to from the space structure. The structure may be spherical, or it may have any desired configuration. Apparatus is provided for separately storing and also for mixing the materials prior to injection thereof into the mold.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a cylindrical canister which may be utilized as an enclosure for the space structure mold of the present invention.
FIG. 2 is a view of the canister of FIG. 1 illustrating an embodiment of the invention with the canister in its separated condition and with a spherical mold exposed to space and formed to its final predetermined configuration. A space vehicle is shown utilizing one end section of the canister as a docking facility.
FIG. 3 is a partial sectional view taken along line 3--3 of FIG. 2 illustrating an embodiment of the invention with the space structure constructed in layers and forming an environmental habitat.
FIGS. 4 and 5 are diagrammatic views of a storage tank for chemically hardenable materials and a mechanical pumping arrangement for pumping the materials into a mixing device. FIG. 4 illustrates the storage tank having an inner container fully expanded by the materials therein. FIG. 5 illustrates a semi-collapsed state of the container as the materials are being discharged.
FIGS. 6 and 7 are views similar to FIGS. 4 and 5, respectively, wherein a gas pressure-pumping device is used to discharge the materials.
FIG. 8 is a diagrammatic elevational view of the mixing device for mixing the hardenable chemicals received from the storage tanks.
FIG. 9 is a pictorial view illustrating the reinforcing and spacing assembly used in the mold of the present invention.
FIG. 10 is an exploded pictorial view of an interior-to-exterior connection assembly which may be used to make necessary interior-to-exterior connections through the shell assembly.
FIG. 11 is a diagrammatic, exploded pictorial view similar to FIG. 10 showing a porthole, airlock, or injector manifold for mounting in the interior-to-exterior assembly of FIG. 10.
FIG. 11a is a pictorial view of an injector manifold.
FIG. 12 is a partial pictorial view of the core assembly of FIG. 10, modified to receive the injector assembly for injecting the chemically hardenable materials into the mold.
FIG. 13 is a pictorial view of a truss structure, made in accordance with the principles of the present invention, for supporting solar cells, communication antennas, and other space structures.
FIG. 14 is an enlarged pictorial view of the structure of FIG. 13 illustrating the joint between the structural tubular members and the manner in which mounting bolts and electrical cables are carried by the structure.
FIGS. 15, 16, and 17 are pictorial views illustrating barrel, honeycomb, and circular parabolic configurations which may be attained by utilizing the principles of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As seen in FIG. 1, an enclosure 2 for placing a mold 4 into space includes a cylindrical canister comprised of a pair of sections 6 and 8 which are secured together prior to launch and separated after reaching orbit. The mold is collapsed and folded in the canister or container on Earth and, subsequent to being placed in orbit, the mold 4 is formed and takes the shape of its desired configuration. A spherical shape is illustrated in FIG. 2; however, other shapes may be used as desired. Forming is accomplished by injection of chemically hardenable materials in the mold. As illustrated in FIG. 2, the container sections 6 and 8 separate and remain with the habitate to serve as a docking airlock for astronauts, or not, depending on the launch configuration. If desired, at least one of the container sections may serve to carry the pumps, storage tanks, and equipment needed for the chemicals. The container is separated in space by any of many known types of separation devices (springs, etc.).
In the embodiment shown in FIG. 3, a multi-layered spherical construction is illustrated with the multi-layered mold formed. The mold 4 includes mold layers 10, 12, 14, 16, 18, 20, and 21. A plastic filter insulating layer 22 is disposed between moldlayers 10 and 12, and insulating layers 24 and 26 are disposed between mold layers 12 and 14, and 16 and 18, respectively. Layers of reinforced epoxy 28 and 30 are disposed between layers 14 and 16, and 18 and 20, respectively. Structural reinforcing members 32 are positioned between layers 16 and 18 of the mold. Members 32 are an integral part of the mold and are foldable for enclosure in the mold in its collapsed position and extended in the inflated position of the mold. The portions of the structure which are not part of the hardened shell (the interior of layer 10, for example, in FIG. 3) are to be filled with a gas or liquid to provide for holding the shape of the old during the hardening or "setting" period for the filler materials in the shell.
To provide the space structure with means for electrically connecting external sensors and communication devices with the interior of the space structure, a conduit 34 is mounted in the layers of the mold during assembly thereof on the ground. The conduit extends from the interior 36 of the structure to the exterior thereof where communication devices 38 and sensors 40 are mounted. Power lines 42 are positioned in layers 22 and 30 of the filler materials and may include communications, data links, sensors, etc.
To insure uniform layer structure formation, a plurality of structural reinforcement and spacing members 44 are disposed in the mold. A plurality of spacers 46 are provided in each layer of the mold and are respectively secured to each section 48 of reinforcing member 44 (FIGS. 3 and 9).
To provide shock and impact resistance to the space structure, a layer of Kelver™, or similar material 50 is disposed in between the outer layers 20 and 21 of the mold (FIGS. 3 and 12).
Also, if desired, a flexible metallic wire mesh or screen may be disposed between the layers. The metal should be sufficiently flexible for the mold to conform to the predetermined shapes after the injection of filler materials and the gas inflation processes is begun. This provides a metallic structural reinforcement for the shell structure.
FIGS. 4 and 5 illustrate the means for mechanically pumping the filler materials into the mold. A full storage tank 52 is illustrated in FIG. 4 and is provided with a pump 54 which communicates with the interior of a collapsible container 56 which is secured in the interior of the container by tethers 58. A monitoring valve 60 is mounted in the discharge pipe 62 from the container to control flow of the filler material from the storage tank. FIG. 5 illustrates the container partially empty.
A gas-pressure pumping scheme is illustrated in FIGS. 6 and 7. In this pumping arrangement, a source of gas under pressure 64 communicates into storage tank 52 to apply pressure to container 56 to force the filler materials out of collapsible container 56 through monitoring valve 60 and discharge pipe 62. FIG. 7 illustrates the container partially empty.
A mixing device 66 is connected to the discharge pipe 62 of each storage tank to receive the filler materials therefrom for mixing thereof and for injecting the mixture into the mold form. The mixing device includes a mixing tank 68 having discharge lines 62 from the container secured thereto. A plurality of spaced, radially extending blades 70 are secured to shaft 72 of a motor 74 for rotation thereby. End bearings 76 and 78 support the shaft in the mixing tank. A discharge pipe or line 80 directs the mixed filler materials out of the mixing tank and into the mold. The flow of the filler materials is monitored by flow monitor valves 60 going into the mixing tank and discharge monitor/check valves 82 as the flow exits the mixing tank through discharge line 80 (FIGS. 11 and 11a).
As more clearly seen in FIG. 9, the reinforcing and spacing assembly 44 includes spacers 46 placed on a rod 48 in spaced relation. The spacers include flangs 88 and 90 at opposite ends thereof. A pair of end flanges 92 is secured to opposite ends of members 46 by being bolted into tapped holes in member 46. The mold layers are gripped between adjacent flanges, and the reinforcing and spacing assembly is glued and/or bolted together on Earth. The reinforcing members are distributed uniformly throughout the mold structure in order to ensure that the layers of filler materials have a uniform thickness where such uniformity is desired. If desired, the flanges may not be integral with the spacer but may be washers placed around rod 48 at the ends of each spacer.
To provide a means for mounting interior-to-exterior structures in the shell, such as a hatchway, port, interlock or an interior-exterior structural member (FIGS. 10, 11, and 12), a layerd ring structure 94 is mounted through the mold assembly. The layered ring structure includes a cylindrical core member 96 having a flange 98 at the upper end thereof and a termination ring 100 at the lower end. A plurality of ring members 97 is positioned around the core member in spaced relation. The rings 97 are positioned so that adjacent rings secure a mold layer between them. Core member 96 and rings 97 are assembled into the prefabricated mold structure while on Earth. The rings may be secured to each mold layer by screws or by gluing. The complete core and ring assembly is secured together by bolts 101. Appropriate covers may be installed as required either before or after the mold has formed to its predetermined configuration.
FIG. 11 illustrates the use of core member 96 for receiving exterior-to-interior assemblies, such as a porthole 102, an airlock 104, or an injector assembly 106 for injecting the filler materials into the mold. When used as a porthole, sealed glass assemblies 108 and 110 are secured in spaced relation around core 96 at the inner and outer surface thereof.
To provide a means for injecting the hardenable chemicals into the mold, lines 80 from each mixing tank 68 are secured to manifold 106 (FIG. 11a). The manifold 106 is positioned in the core 96 of a modified ring structure 94 with lines 80 communicating between the layers of the mold through holes 108 provided through injector assembly 106 and holes 109 provided in rings 97. As seen in FIG. 12, injector assembly 106 is modified to include the holes 108 to receive the ends of the exit lines 80, and the ring members have been provided with holes 109. The manifold is to be left in the core after the injection process has been completed. The lines 80 into the manifold are disconnected (via a quick disconnect coupling 110) (FIG. 11) and an appropriate cover then installed over the core opening. To prevent backflow of the chemicals during the injection process, and while waiting for the chemicals to harden, lines 80 are provided with the monitor/check valves 82 as shown in FIG. 11a.
While the interior-to-exterior structure has been illustrated to be cylindrical, it is to be understood that other configurations may be restored to. Such configurations may be triangular, rectangular, oval, etc.
It is to be understood that, while a spherical structure utilizing multiple layers of mold materials and hardenable filler materials has been described, a structure using a single layer of hardenable materials may be restored to, if desired. The configuration may be any of many desirable configurations.
In the embodiment shown in FIGS. 13 and 14, the mold 112 is formed on Earth in the shape of tubes arranged for use as a structural member, such as an antenna or solar cell support structure. The structure includes a plurality of tubes 114 secured together by tubular struts 116. FIG. 14 illustrates the manner in which electrical cables 118 and mounting bolts 120 are secured in the structure.
The tubular plastic is formed on Earth with the electrical wiring built into the mold and the mounting bolts made part of the mold. The structure is made flexible and "folded" for launch. In space, the hardenable filler materials are injected at pressures sufficient for the mold to hold its shape until after it hardens. The structure may be attached to other frameworks, such as the habitat as described above, either before or after the chemicals harden in the structural member.
While the structural truss is illustrated in FIGS. 13 and 14 as having a triangular configuration, it is to be understood that other configurations may be restored to without departing from the scope of the invention. FIG. 15 illustrates a barrel structure, FIG. 16 illustrates a honeycomb-type of structure, and FIG. 17 illustrates a circular parabolic structure which may be formed according to the principles of the present invention.
It is to be understood that the filler materials used depend on the desired property:
Structural filler - rigidity, strength, hardness;
Insulating filler - heat, light, electricity;
Radition filler - radiation resistance;
Conduction filler - radio/microwave shielding; and
Impact filler - impact resistance (meteors).
The filler materials may be epoxy resins, polyurethane, latex, mylar, cement, ceramic mix, polyamide-imides, and the class of plastics known as ABS.
The mold may be made of plastic films, sheets, and fabrics (the sheets and fabric need not be plastic) and must be non-leaking. The mold is assembled on Earth by gluing, thermally sealing, or clamping many smaller pieces together. Mechanical interconnections for air, water, sewage, valves, airlocks, spouts, and other structures or fixtures may be attached to or constructed as part of the mold. The mold must be impervious, flexible, and non-elastic.
It is apparent that the apparatus of the present invention provides a means whereby the properties of space are utilized, specifically a vacuum and no effective gravity for orbiting bodies, for the construction of environmental habitats and/or protective shells and/or reinforcing structures for such things as equipment and people. The principles of the present invention allow single-piece fabrication in space without launching smaller pieces and assemblying them in space or launching large cumbersome structures which have been "beefed up" to withstand the stress of launch.
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A space structure which is formed in space. The structure is comprised of an expandable, flexible, generally non-elastic, impervious mold which is arranged in a collapsed state in a container which separates in space to expose the mold to the space environment. The mold is formed to a predetermined configuration by the injection of chemically hardenable filler materials. The vacuum properties of space permit very low injection perssues for the injection process, and the non-gravitational properties of space permit the mold to remain substantially sag-free during hardening of the filler materials.
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OBJECT OF THE INVENTION
The invention relates to a new removable floor comprising a support of variable dimensions and formats on which a floor tile is glued, said floor tile can be made of any suitable material such as marble, granite, ceramic, wood, etc., and in which said support is provided with joints in order to produce the attachment between different supports, and consequently cover a surface with the floor tiles. Its aim is to provide the possibility of modifying the ergonomic properties of the floor at will, facilitating the laying, removing, replacement, maintenance or exchange of floors, as well as permitting the laying of supports out of phase and/or aligned in order to achieve different decorative motifs.
Another aim is to permit the passage of cables and pipes underneath the support.
PRIOR ART OF THE INVENTION
In the state of the art, the laying of flooring by means of masonry work, requiring the gluing of the floor tiles and coating, over the surface to be covered, with different adhesives, generally in the presence of water, is known, which means that users cannot make any redecorations, replacements or changes of floors and walls with the frequency and will they might wish.
In order to solve this problem, the use of removable floors is known in the state of the art, which comprises a support on which the floor tile is glued, having the support means of joint in order to produce the attachment of the different supports and consequently the laying of the floor tiles, which considerably facilitates the laying/removing of them by the user, permitting permanent and even seasonal use of the floor tiles, this is, during different times of the year and which above all eliminates the earlier mentioned traditional methods of laying.
In this regard, international application WO 03/040491 can be cited in which a removable floor is described consisting of a support with supports manufactured in plastic on which a floor tile or decorative surface is adhered, with two abuting lateral faces of the support having separate upper longitudinal extensions and separate lower longitudinal extensions, among them a curved recess forming a housing is defined; while the other two abuting lateral faces of the support include each other middle longitudinal extensions that are introduced into the housing defining a joint. This configuration presents the drawback that the joint is not optimised, which means that the floor is not ergonomically optimum and could be improved. Moreover, according to one embodiment, the housing is defined by an approximately circular orifice in which fits a complementary curved thickening provided in the middle extension which requires considerable pressure in order to fit the different supports together.
DESCRIPTION OF THE INVENTION
In order to solve the drawbacks and achieve the objectives stated above, the invention has developed a new removable floor, which, as well as those contained in the state of the art, comprises a support piece on which a floor tile of any suitable material, is glued, being said material such as marble, granite, ceramic, etc., all this in such a way that the support piece includes means of securing in order to create the joint between the different supports, and consequently cover the surfaces by means of the floor tiles which are glued to the supports; said means of securing in two abuting lateral faces of the support consisting of separate upper longitudinal extensions and separate lower longitudinal extensions in such a way that they both define a housing; and in the other two abuting lateral faces of the support piece is made for the means of securing to consist in separate middle longitudinal extensions that are introduced into the housing in order to lay the floor.
The present invention is characterised in that the middle longitudinal extensions include a thickening at their end defined by a body with a curved shape which is joined to the middle zone of the side walls of the support by means of a set of equidistant sections; having made the provision for the lower extensions to consist in at least two flanges of width less than or equal to that of the upper longitudinal extensions; and which are provided with a curved longitudinal recess; and in that the lower face of the upper longitudinal extensions include a curved longitudinal recess facing the curved longitudinal recess of the lower extensions, in order to define the housing of the curved body of the middle longitudinal extensions. Moreover, the lower faces of the upper longitudinal extensions include a longitudinal bevel in their front end in order to facilitate the introduction of the curved body. The invention is also characterised in that the floor tiles are glued in a position selected among one in which the two lesser abuting sides of those floor tiles are coplanar with the corresponding lesser sides of the support, and the other two opposite sides of the floor tiles remain out of phase with respect to the corresponding sides of the support in order to define a joint between the floor tiles when they are being laid, the width of which depends on that phase difference, or a position in which the floor tiles are head joined depending on the manufacturing dimension of the floor tiles.
In one embodiment of the invention provision is made for the upper longitudinal extensions to include openings by way of windows in the zones facing the flanges.
The lower face of the support pieces comprises a set of retention fittings consisting on removable stoppers for support of the supports. The use of these stoppers is optional because the fittings can, if wished, serve to secure the supports to the substrate by means of screws, suction pads or similar securing elements.
Moreover, one embodiment of the invention provides for the lower face of the support pieces to include lateral and/or diagonal ribs for acting as a support for the support pieces in the event that the removable stoppers are not used. These ribs can present projections in order to hinder the slipping of the pieces in the event of their laying on a flexible substrate.
The fitting in which the removable stoppers are held back is, according to another embodiment of the invention, made in certain projections which cause the rising up of the support piece in order to allow pipes and cables to pass beneath those support pieces.
Complementary or alternatively to these elevation projections, the lower face of the support pieces is provided with some elevation partitions for allowing pipes and cables to pass beneath the support pieces.
In the preferred embodiment of the invention, the lower extensions of the support pieces are defined by a set of equidistant flanges in which the thickening defined by the curved shape body fits under pressure.
Furthermore, in the preferred embodiment of the invention provision is made for the support piece to consist of a grille including the different elements described above.
In the event that the floor tiles are arranged separately defining a joint, said joint is filled using any conventional method.
The configuration described permits the grilles to be arranged aligned and/or out of phase with respect to others in order to achieve different decorative motifs, such as a herringbone pattern for example.
In addition, the inventive floor has the advantage of providing thermic or acoustic insulation, permitting liquids to drain and eliminating the appearance of damp patches. The fact that the inventive floor is removable means that it is accessible and can be laid permanently or temporarily in different spaces, such as stands, commercial premises, etc.
Finally, the fact that mortar or chemical adhesives are not used in laying the floor tiles confers to the invention considerable ecological and sustainability characteristics, thanks to the ease of recycling and recovery of its components.
Below, in order to facilitate a better understanding of this specification and being an integral part thereof, a series of figures are attached in which, on an illustrative rather than limiting basis, the most characteristic details of the invention have been represented.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 .—Shows a perspective view of the lower face of the grille constituting the support piece.
FIG. 2 .—Shows a perspective view of the lower face of a detail of the grille of FIG. 1 where the configuration of the removable stoppers, along with the means constituting the joint for the different grilles can be seen.
FIG. 3 .—Shows a partial perspective view of the upper face of the grille.
FIG. 4 .—Shows a partial view in cross-section of an example of union between two grilles for the case in which the floor tiles are laid separated by a distance defining a joint.
FIG. 5 .—Shows a partial view in cross-section of an example in which the floor tiles are joined head on.
FIG. 6 .—Shows a schematic view of a possible embodiment of a floor tile mounted on the grille. The phase difference between two of the abuting sides of the floor tile with respect to those of the grille determines whether or not the floor tiles form a joint after being laid.
FIG. 7 .—Shows an example of embodiment of the inventive grille for the case in which cables or pipes are required to pass underneath them.
FIG. 8 .—Shows a schematic view of a possible embodiment in which the floor tiles are laid alternatively out of phase to each other, for which the grilles are laid adopting this phase difference. This example could adopt any other configuration according to the desired decorative motif, since the grilles can be moved around with respect to one another.
FIG. 9 .—Shows a schematic view of a possible embodiment in which the floor tiles and grilles adopt different sizes in order to adapt themselves to different surfaces, and/or to define different decorative motifs.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Given below is a description of the invention based on the figures previously commented.
The invention comprises a support 1 consisting of a grille 1 with two abuting sides including some middle longitudinal extensions 2 which are defined by a set of equidistant sections 4 which attach a thickening 3 , defined by a curved shape body, to the middle zone of the sides of the grilles 1 .
Provided on the other two abuting sides of the grilles 1 are separate upper longitudinal extensions 5 and separate lower extensions which are determined by flanges 8 equidistant to each other.
The upper longitudinal extensions 8 are endowed in their rear part of the lower face with a curved recess 6 which faces a curved recess 9 provided in the lower face and rear part of the flanges 8 .
Moreover, the front edge of the lower face of the upper longitudinal extensions 5 includes a longitudinal bevel 7 which projects with respect to the flanges 8 , for which these flanges have a width narrower than the upper longitudinal extensions 5 ; all this in order to facilitate the engagement of the middle longitudinal extensions 2 in the housing defined by the curved recesses 6 and 9 which are respectively provided in the upper longitudinal extension 5 and the flanges 8 .
In order to carry out the joint of the grilles to each other, the thickening 3 is located on the bevel 7 and it is then pressed until said thickening 3 is introduced into the curved recesses 6 and 9 . This operation is favoured by the arrangement of the flanges 8 which, due to being short in length and width, facilitate the introduction of the thickening into the curved recesses 6 and 9 under pressure.
Stuck on top of each grille 1 there is a floor tile 15 as it will be described further below, in such a way that when the different grilles are joined together the surfaces become covered, quickly and simply, by the floor tiles.
In order to carry out the support for the grilles over the surface to cover, provision is made for their lower face to include a set of lateral 11 and diagonal 12 ribs for reinforcement and support over the surface to cover.
In another embodiment of the invention, provision is made for the lower face of the grille to include some retention fittings 13 consisting in removable stoppers 14 which project slightly with respect to the lateral 11 and diagonal 12 ribs in order to produce the support of the grilles. These removable stoppers 14 are made of rubber or any other flexible material.
The invention foresee the possibility (not represented in the figures) of locating a grille on a substrate prepared for this purpose which allows the reception of the grilles.
Another possibility is that very often it is necessary to pass cables or pipes underneath the floor, in such case the lower faces of the grilles contain partitions 17 which raise up the grille at a sufficient height for allowing the passage of cables and pipes beneath the lower part of that grille.
For the case in which it is required to allow the passage of pipes and cables beneath the grille, the invention foresee the incorporation into the lower face thereof of some elevation projections 18 in which the removable stoppers 14 are inserted, constituting said removable stoppers the support points for the grille.
As already mentioned above, the floor tiles 15 are glued on to the grilles 1 , but it can be highlighted that this joint is carried out selectively, so that the floor tiles remain separated from each other, defining a joint between them which is filled in the conventional way, or in order to get the floor tiles 15 to be joined head on, according to their manufacturing dimension.
So, in the example of embodiment of FIG. 4 , the floor tiles have a dimension such that when the joint between the grilles takes place, a gap 16 remains between then, defining said joint.
This is achieved when the two smaller abuting sides 19 and 20 of said floor tiles are coplanar with the corresponding smaller sides of the support 1 , the other two opposite sides 21 and 22 of the floor tiles 15 being those that are out of phase with respect to their corresponding sides of the support, in order to modify the width of the joint 16 , or so that the floor tiles remain joined head on depending on the manufacturing dimension of them.
In this way, provision is made so that the joint can have a different width, and it can even disappear, as shown in FIGS. 5 and 6 , and, depending on their size, the floor tiles 15 can be joined head on or, on the contrary, they can form a joint 16 of selectable width at all times depending on the size of the floor tiles 15 .
FIG. 9 shows different sizes of floor tile and grilles for being adapted to the surface to cover, and/or for producing different decorative motifs.
The configuration described permits the grilles to be laid out of phase with respect to the others in the longitudinal and/or transverse direction, with which the floor tiles are equally out of phase between each other, as shown, for example, in FIG. 8 .
The ribs 11 , 12 can have projections 23 which hinder the movement of the pieces in the event of their being laid on a flexible substrate.
Finally, it can be highlighted that the set of equidistant sections ( 4 ) show lower support extensions ( 10 ) with the aim of preventing them from bending once the floor has been laid. Said extensions define a support plane ( 25 ) that is coplanar with the rest of the surface for seating the grille ( 1 ).
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A removable floor includes a support piece ( 1 ) having a floor tile ( 15 ) affixed to the upper surface thereof, with the support piece being equipped to be secured to other support pieces, in order to facilitate the installation and removal of the floor by the user and to enable the supports to be installed in an aligned and/or out of phase manner such as to produce different decorative patterns.
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DETAILED DESCRIPTION OF THE INVENTION
1. Field of Art of the Invention
The present invention relates to a rotary gad for a ground drill and more particularly to a rotary gad provided at the front end of a ground drill for drilling the ground to bury pipes or the like in the ground in such works as water supply equipment, drainage equipment and piping for telephone, electricity and gas supply.
2. Background of the Invention
In the conventional ground drilling works for piping, etc. using a hydraulic machine and other equipment, a screw or a driving pipe is rotated, or the whole of a driving pipe equipment provided with such screw or driving pipe is rotated for driving and drilling.
In this case, however, the machinery and equipment are large-scaled, and therefore cannot be used a narrow place, and also in point of cost there has been a problem. Further, the driving and drilling method using a gad fixed to a driving pipe involves the problem that the driving direction is very unstable due to a change in the angle of the gad tip, distortion of the driving pipe, a change in the mounting angle of a hydraulic cylinder, etc. or a change in the nature of the soil.
OBJECT OF THE INVENTION
The present invention, which has been proposed to overcome the above-mentioned problems, aims at providing a ground drill gad wherein the gad alone is rotated to stabilize the driving and drilling direction and thereby operates in an exact manner.
SUMMARY OF THE INVENTION
According to the present invention there is provided a rotary gad for a ground drill, comprising a thick base portion; a body portion contiguous to the base portion, the body portion having a gad tip formed at an acute angle at the front end thereof; a plurality of spiral blades formed on the peripheral wall of the body portion; a hollow portion formed in the interior of the gad; and a core rod disposed within the hollow portion, the gad being rotatable about the outer periphery of the core rod. Also provided is a rotary gad for a ground drill, comprising front and rear rotary gad sections contiguous to each other, the front rotary gad section comprising a thick base portion; a body portion contiguous to the base portion; the body portion having a gad tip formed at an acute angle at the front end thereof; a plurality of spiral blades formed on the peripheral wall of the body portion; a hollow portion formed in the interior of the front gad section; and a core rod disposed within the hollow portion, the front rotary gad section being rotatable about the outer periphery of the core rod, the rear rotary gad section comprising a thick base portion; a body portion contiguous to the base portion, the body portion having spiral blades formed on the peripheral wall thereof, the spiral blades extending in a direction opposite to the spiral direction of the spiral blades of the front rotary gad section; a hollow portion formed in the interior of the rear gad section; and a core rod disposed within the hollow portion, the rear rotary gad section being rotatable about the outer periphery of the core rod in a direction opposite to the rotating direction of the front rotary gad section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the whole of a rotary gad;
FIG. 2 is a longitudinal sectional view thereof;
FIG. 3 is a partial, longitudinal sectional view of a rotary gad according to another embodiment of the invention;
FIG. 4 is a partial, longitudinal sectional view showing a further embodiment;
FIG. 5 is a perspective view of the whole of a rotary gas having a two-stage construction;
FIG. 6 is a longitudinal sectional view thereof;
FIG. 7 is an enlarged view of portion A in FIG. 6; and
FIG. 8 is an enlarged view of portion B in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described in detail hereinunder with reference to the accompanying drawings.
FIG. 1 is an entire perspective view of a rotary gad. The gad, indicated by the reference numeral 1, rotates about a core rod 7. This is based on the following construction. The core rod 7 is positioned within a hollow portion 19 formed in a body portion 3; a core rod stop 5 is retained at the front end thereof by an inner wall 20 of the base portion and at the rear end thereof by a nut 6 which is fitted into the base portion 8 threadedly from behind and fixed thereto with a set-screw 9; and a ball 2 is disposed between the front end of the hollow portion 19 and that of the core rod 7 to ensure rotation at the front end of the core rod 7.
When the core rod 7 pushes the ball 2, the gad 1 rotates under the pressure of the earth applied to spiral blades 4. The ball 2 is for minimizing the contact pressure between the front end face of the hollow portion and that of the core rod to facilitate the rotation of the gad. To this end, it is necessary that the contacting faces with the ball 2 be each in the form of a semi-spherical configuration.
In place of using the ball 2 there also may be adopted such constructions as shown in FIGS. 3 and 4 wherein one of the front end face of the hollow portion and that of the core rod is formed in the shape of a semi-spherical concave and the other in the shape of a semi-spherical convex and both are rotatably contacted with each other. This construction is also effective. FIG. 3 illustrates an embodiment wherein the front end face of the hollow portion is formed in the shape of a semi-spherical concave 13 and that of a core rod 17 in the shape of a semi-spherical convex 14, while FIG. 4 illustrates an embodiment wherein the front end face of the hollow portion is formed as a semi-spherical convex 15 and that of a core rod 18 as a semi-spherical concave 16.
A bearing 12 is for reducing the contact resistance between the core rod 5 and the nut 6 when pulling out the gad 1 halfway and for preventing a driving pipe or any other member from being unscrewed by reverse rotation of the gad 1. Inside the nut 6 is disposed an O-ring 11 which is provided for preventing the leakage of oil from the interior of the gad and also preventing the ingress of water, sand, etc. from the exterior into the gad.
Under such construction, the core rod 7 pushes the ball 2 when driving force is exerted thereon, whereby the ground is drilled. In this case, the contact point of the pressure applied to the core rod 7 is always on the ball 2 positioned near the front end of the gad even when the driving and drilling distance is long, so that the driving and drilling direction is very stable without deviation even upon distortion of the core rod 7, change in the nature of the soil or other changes. In order to enhance stabilization it was better that the gad tip 10 does not project so too much from the front end of the spiral blades 4.
Reference will now be made to the results so far obtained in actual use of the rotary gad at fifty-two places with water supply pipe taking-out. The operation were conducted under the following condition. An asphat-paved road 8.3 m wide saved on a pebble-mixed red earth layer, a water supply pipe positioned 0.8 m from the shoulder, and a drilling width of 7.2 m exclusive of a working width of 1.1 m. The time required for drilling and piping was about three hours (two plumbers). In the case of excavation for the same road conditions, there were required workers for asphalt cutting, roadbed chipping and operation of a small-sized back hoe, as well as workers for plumbing, traffic control, removal of surplus soil and temporary restoration of the road surface, which required additional six workers, and about six hours was required for the work. According to the present invention, the number of workers required is reduced to one sixth; besides, the workers and materials for the restoration of the road surface are no longer necessary, so a great reduction in cost can be attained. Additionally, the operation can be completed in a short period without damage to the road surface and without being an obstacle to traffic.
Also when filled earth a gravel layer with red clay mixed therein was drilled over a length of 3 m at depths of 100 mm, 75 mm and 50 mm, there was obtained a similar effect.
Another embodiment of the present application is shown in FIGS. 5 to 8. A rotary gad according to this invention is of a two-stage construction of front and rear sections, one of which rotates in a forward direction and the other rotates in the reverse direction about core rods 25 and 43. This is because of the following construction. The core rod 25 is positioned within hollow body portions 24 and 35; a core rod stop 26 is retained at the front part thereof by the inner wall of a base portion while in a rear position, a stop screw 38 is connected to the rear end of the core rod 25, which stop screw is in pressure contact with a pushing portion 41 through a ball 40. The core rod 43 is positioned within the hollow portion 35 and a core rod stop 43 thereof is retained at the front part thereof by the inner wall of a base portion while the rear part thereof is retained by a nut 46 which is fitted into the base portion threadedly from behind and fixed to the base portion with a set-screw 45; and there are disposed balls 22, 40 and 42, whereby the body portions 24 and 35 are rendered rotatable.
When the core rod 25 pushes the ball 22, the body portion 24 rotates by virtue of the pressure of the earth exerted on spiral blades 23. The ball 22 is for minimizing the contact resistance between the front end face of the hollow portion and that of the core rod to facilitate the rotation of the body portion 24. To this end, it is necessary that the faces in contact with the ball 22 be each formed in the shape of a semi-spherical concave.
On the other hand, when the core rod 43 pushes the ball 42, the body portion 35 rotates by virtue of the pressure of the earth exerted on spiral blades 36. Besides, since the spiral direction of the blades 23 and that of the blades 36 are opposite to each other, one rotates in a forward direction and the other rotates in the reverse direction. Consequently, there are attained a total of twice the revolutions as the revolutions only in one direction, thus affording an extremely high accuracy in the drilling direction. In this connection, it became clear that if the torsional angle of the spiral was made too large, it would result in adhesion of soil to the spiral blades and hindrance of the rotation.
The body portions 24 and 35 are coupled together through a coupling 32. An O-ring 33 is disposed in the coupling for the protection of the core rod 25. Further, the coupling 32 is fixed to the body portion 35 with a set-screw 34. Numeral 31 denotes an O-ring.
A core rod stop screw 28 is threadedly fitted into the body portion 24 and is fixed with a set-screw 30. Numeral 29 denotes an O-ring.
A bearing 27 is provided for reducing the contact resistance between the core rod stop 26 and the coupling 32 when pulling out the gad halfway and for preventing a driving pipe or any other member from being unscrewed by reverse rotation of the gad.
A bearing 44 also fulfills a similar function. A nut 46 is threadedly fitted into the base part of the body portion 35 and is fixed with a set-screw 45. Inside the nut 46 is disposed an O-ring 47 which is for preventing the leakage of oil from the interior of the gad and also preventing the ingress of water, sand, etc. from the exterior into the gad.
A cylinder 37 is provided for connecting the core rod 25 and the body portion 35 at the time of pulling out the gad. The stop screw 38 is fixed to the core rod 25 through a setscrew 39 and engages the pushing portion 41 through the ball 40. The set screw 39 prevents the cylinder 37 from coming off the core rod 25.
With such a construction, when a driving force is exerted on the core rods 43 and 25, these rods push the balls 42, 40 and 22, whereby the ground is drilled. In this case, even if the driving and drilling distance becomes longer, there is attained a very high accuracy of the driving and drilling direction because the contact point of the pressure applied to the core rods 43 and 25 is always on the ball 22 positioned near the gad tip 21 and also because of the long body. Besides, the adhesion of soil to the spiral blades due to the long body can be kept to a minimum because the rotating direction of the spiral blades 23 and that of the spiral blades 36 are opposite to each other.
According to the present invention, as set forth hereinabove, there is also proposed a construction whereby a driving pressure is provided in the vicinity of the front end of the gad and wherein the body portion is made long and the rotating direction of the spiral blades is varied. Consequently, it is possible to provide a rotary gad for a ground drill capable of operating in an exact manner at low cost in a short period while stabilizing the driving and drilling direction even under adverse conditions.
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A rotary gad for a ground drill includes an elongated front body having a front end and a rear end with front spiral blades being disposed on the outside of the front body. The front body has an elongated front axial passage, and a front core rod is disposed in the front axial passage. The front body is rotatable about the front core rod. The front core rod has a front end and a rear end. An elongated rear body has a similar construction and a pushing section is provided on a rear axial passage in the rear body. The pushing section has a front side and a rear side. A rear ball element is disposed between the rear side of the pushing section and the front end of a rear core rod, and a front ball element is disposed between the front side of the pushing section and the rear end of the front core rod. Coupling means couple the front and rear bodies to provide for rotation of the front and rear bodies in opposite directions about the front and rear core rods.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application No. 61/828,820 filed May 30, 2013, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a crystalline form of N,N-dicyclopropyl-4-(1,5-dimethyl-1H-pyrazol-3-ylamino)-6-ethyl-1-methyl-1,6-dihydroimidazo[4,5-d]pyrrolo[2,3-b]pyridine-7-carboxamide, a JAK2 inhibitor currently in clinical trials for the treatment of myeloproliferative disorders, which include polycythaemia vera, thrombocythaemia and primary myelofibrosis.
BACKGROUND OF THE INVENTION
[0003] N,N-dicyclopropyl-4-(1,5-dimethyl-1H-pyrazol-3-ylamino)-6-ethyl-1-methyl-1,6-dihydroimidazo[4,5-d]pyrrolo[2,3-b]pyridine-7-carboxamide, has the structure of formula I:
[0000]
[0004] Compound I, compositions comprising Compound I, and methods of using Compound I are disclosed in U.S Pat. No. 8,202,881 B2, which is assigned to the present assignee and is incorporated herein by reference in its entirety.
[0005] Typically, in the preparation of a pharmaceutical composition, a form of the active ingredient is sought which has the desired solubility and bioavailability and has sufficient stability that it does not convert during manufacture or storage of the pharmaceutical composition to a different form having different solubility and/or bioavailability. A form of Compound I is desired having properties and stability that allow the preparation of pharmaceutical compositions suitable for the treatment of diseases such as cancer.
SUMMARY OF THE INVENTION
[0006] In one embodiment, the compound of Example 1
[0000]
[0000] is provided as a crystalline material comprising the first crystalline form. The first crystalline form of the compound of Example 1 comprises a neat crystalline form referred to herein as “Form T1H1.5-4” or “T1H1.5-4 Form” of Example 1.
[0007] In one embodiment, the T1H1.5-4 Form of Example 1 is characterized by unit cell parameters approximately equal to the following:
[0008] Cell dimensions:
a=8.8065(6) Å b=11.4967(8) Å c=23.2201(13) Å α=81.044(5)° β=84.070(5)° γ=89.994(6)°
[0015] Volume=2309.5(3) Å 3
[0016] Crystal system: Triclinic
[0017] Space group: P-1
[0018] Molecules/asymmetric unit: 2
[0019] Density (calculated)=1.244 Mg/m 3
[0020] Measurement of the crystalline form is at a temperature of about 23° C.
[0021] In another embodiment, the T1H1.5-4 Form is characterized by a simulated powder x-ray diffraction (PXRD) pattern substantially in accordance with the pattern shown in FIG. 1 and/or by an observed PXRD pattern substantially in accordance with the pattern shown in FIG. 1 .
[0022] In yet another embodiment, Form T1H1.5-4 may be characterized by a powder X-ray diffraction pattern comprising the following 2θ values (CuKαλ=1.5418 Å): 3.9±0.2, 12.7±0.2, 13.8±0.2, 14.7±0.2, 15.6±0.2, 18.8±0.2, 25.4±0.2, 26.1±0.2 and 26.9±0.2, at room temperature.
[0023] In still yet an even further embodiment, the T1H1.5-4 Form is substantially pure.
[0024] In still yet another embodiment, the T1H1.5-4 Form contains at least about 90 wt. %, preferably at least about 95 wt. %, and more preferably at least about 99 wt. %, based on weight of the Form T1H1.5-4.
[0025] In yet another embodiment, a substantially pure, T1H1.5-4 Form has substantially pure phase homogeneity with less than about 10%, preferably less than about 5%, and more preferably less than about 2% of the total peak area of the experimentally measured PXRD pattern arising from peaks that are absent from the simulated PXRD pattern. Most preferably, the substantially pure crystalline Form T1H1.5-4 has substantially pure phase homogeneity with less than about 1% of the total peak area of the experimentally measured PXRD pattern arising from peaks that are absent from the simulated PXRD pattern.
[0026] In another embodiment, the crystalline form consists essentially of Form T1H1.5-4. The crystalline form of this embodiment may comprise at least about 90 wt. %, preferably at least about 95 wt. %, and more preferably at least about 99 wt. %, based on the weight of the crystalline form, Form T1H1.5-4.
[0027] In yet another embodiment, a pharmaceutical composition is provided comprising the T1H1.5-4 Form, and at least one pharmaceutically acceptable carrier and/or diluent.
[0028] In still another embodiment, a pharmaceutical composition comprises substantially pure Form T1H1.5-4, and at least one pharmaceutically acceptable carrier and/or diluent.
[0029] In still an even further embodiment, a therapeutically effective amount of Form T1H1.5-4 is combined with at least one pharmaceutically acceptable carrier and/or diluent to provide at least one pharmaceutical composition.
[0030] The names used herein to characterize a specific form, e.g. “T1H1.5-4” etc., should not be considered limiting with respect to any other substance possessing similar or identical physical and chemical characteristics, but rather it should be understood that these designations are mere identifiers that should be interpreted according to the characterization information also presented herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention is illustrated by reference to the accompanying drawings described below.
[0032] FIG. 1 shows observed and simulated powder x-ray diffraction patterns (CuKαλ=1.5418 Å) of the T1H1.5-4 crystalline form of N,N-dicyclopropyl-4-(1,5-dimethyl-1H-pyrazol-3-ylamino)-6-ethyl-1-methyl-1,6-dihydroimidazo[4,5-d]pyrrolo[2,3-b]pyridine-7-carboxamide (Compound I).
[0033] FIG. 2 shows a differential scanning calorimetry thermogram of the T1H1.5-4 crystalline form of Compound I.
[0034] FIG. 3 shows a thermogravimetric analysis (TGA) thermogram of the T1H1.5-4 crystalline form of Compound I.
DETAILED DESCRIPTION OF THE INVENTION
[0035] As used herein, “polymorphs” refer to crystalline forms having the same chemical compositions but different spatial arrangements of the molecules and/or ions forming the crystals.
[0036] As used herein, “amorphous” refers to a solid form of a molecule and/or ions that is not crystalline. An amorphous solid does not display a definitive X-ray diffraction pattern with sharp maxima.
[0037] As used herein, “substantially pure”, when used in reference to a crystalline form, means a sample of the crystalline form of the compound having a purity greater than 90 weight %, including greater than 90, 91, 92, 93, 94, 95, 96, 97, 98, and 99 weight %, and also including equal to about 100 weight % of the compound, based on the weight of the compound. The remaining material comprises other form(s) of the compound, and/or reaction impurities and/or processing impurities arising from its preparation. For example, a crystalline form of Compound I may be deemed substantially pure in that it has a purity greater than 90 weight % of the crystalline form of Compound I, as measured by means that are at this time known and generally accepted in the art, where the remaining less than 10 weight % of material comprises other form(s) of Compound I and/or reaction impurities and/or processing impurities. The presence of reaction impurities and/or processing impurities may be determined by analytical techniques known in the art, such as, for example, chromatography, nuclear magnetic resonance spectroscopy, mass spectrometry, or infrared spectroscopy.
[0038] As used herein, the unit cell parameter “molecules/unit cell” refers to the number of molecules of Compound I in the unit cell.
[0039] When dissolved, the crystalline form of Compound I loses its crystalline structure, and is therefore referred to as a solution of Compound I. Crystalline Form T1H1.5-4 of Compound I may be used for the preparation of liquid formulations in which the compound is dissolved or suspended. In addition, the crystalline Form T1H1.5-4 of Compound I may be incorporated into solid formulations.
[0040] A therapeutically effective amount of the crystalline Form T1H1.5-4 of Compound I may be combined with a pharmaceutically acceptable carrier or diluent to provide pharmaceutical compositions of this invention. By “therapeutically effective amount”, it is meant an amount that, when administered alone or an amount when administered with an additional therapeutic agent, is effective to prevent, suppress, or ameliorate a disease or condition or the progression of a disease or condition.
[0041] Compound I, of the formula,
[0000]
[0000] is provided as a crystalline material comprising the first crystalline form. The crystalline form of compound I comprises a neat crystalline form referred to herein as “Form T1H1.5-4” or “T1H1.5-4 Form”.
[0042] In one embodiment, the T1H1.5-4 Form is characterized by unit cell parameters approximately equal to the following:
[0043] Cell dimensions:
a=8.8065(6) Å b=11.4967(8) Å c=23.2201(13) Å α=81.044(5)° β=84.070(5)° γ=89.994(6)°
[0050] Volume=2309.5(3) Å 3
[0051] Crystal system: Triclinic
[0052] Space group: P-1
[0053] Molecules/asymmetric unit: 2
[0054] Density (calculated)=1.244 Mg/m 3
[0055] Measurement of the crystalline form is at a temperature of about 23° C.
[0056] The crystalline form is a crystalline form of Compound I and is referred herein as the “T1H1.5-4 Form”.
[0057] In a different embodiment, the T1H1.5-4 Form of Compound I is characterized by fractional atomic coordinates substantially as listed in Table 1.
[0058] Table 1. Atomic coordinates (×10 4 ) and equivalent isotropic displacement parameters (Å 2 ×10 3 ) for T1H1.5-4.
[0000]
TABLE 1
Positional Parameters and Isotropic Temperature Factors for
Form T1H1.5−4 of Compound I
Atom
X
Y
Z
U(eq)
C(1)
1574(16)
9113(10)
1094(5)
63(3)
C(2)
715(16)
8665(10)
1626(5)
68(4)
C(3)
−625(15)
8276(10)
1469(5)
64(3)
C(4)
−1640(14)
8155(11)
509(5)
87(4)
C(5)
−1989(14)
7684(11)
1860(5)
92(4)
C(6)
4002(15)
9868(9)
1353(5)
59(3)
C(7)
5454(15)
10387(9)
1125(5)
58(3)
C(8)
6453(15)
10643(9)
1497(5)
58(3)
C(9)
7416(15)
11160(10)
597(5)
66(3)
C(10)
9106(13)
11583(10)
1354(5)
77(4)
C(11)
6099(16)
10393(10)
2121(5)
67(4)
C(12)
4614(17)
9910(10)
2276(5)
67(4)
C(13)
6662(15)
10443(10)
2656(5)
77(4)
C(14)
5547(17)
10044(10)
3098(4)
75(4)
C(15)
2828(17)
9242(13)
3194(5)
98(5)
C(16)
1629(18)
10213(15)
3212(7)
139(6)
C(17)
5490(20)
10063(14)
3742(6)
81(4)
C(18)
7386(19)
8492(19)
3782(7)
122(6)
C(19)
7210(20)
7301(17)
4145(7)
161(8)
C(20)
6570(20)
7505(14)
3561(7)
137(6)
C(21)
6740(17)
9553(14)
4620(5)
107(5)
C(22)
7460(30)
10710(20)
4751(8)
184(12)
C(23)
8260(20)
9520(20)
4833(9)
189(12)
C(24)
6639(14)
4118(9)
1098(5)
54(3)
C(25)
5823(15)
3678(10)
1620(5)
63(3)
C(26)
4449(15)
3325(10)
1502(6)
67(3)
C(27)
3389(13)
3207(11)
538(5)
86(4)
C(28)
3106(14)
2740(10)
1876(5)
85(4)
C(29)
9108(13)
4844(9)
1330(5)
54(3)
C(30)
10534(13)
5410(9)
1107(5)
52(3)
C(31)
11506(13)
5693(9)
1487(5)
54(3)
C(32)
12423(16)
6221(10)
574(5)
74(4)
C(33)
14133(13)
6678(10)
1314(4)
75(4)
C(34)
11152(14)
5454(10)
2099(5)
60(3)
C(35)
9713(14)
4902(10)
2251(5)
62(3)
C(36)
11781(14)
5599(10)
2615(5)
72(4)
C(37)
10773(16)
5131(11)
3071(5)
74(4)
C(38)
8110(18)
4092(16)
3167(5)
129(7)
C(39)
8500(20)
2836(16)
3355(9)
197(10)
C(40)
10716(19)
5173(12)
3711(5)
79(4)
C(41)
13450(20)
4624(17)
3713(6)
116(5)
C(42)
14060(20)
3570(20)
4060(8)
176(8)
C(43)
13430(20)
3498(17)
3497(7)
170(9)
C(44)
11968(15)
5293(13)
4559(5)
89(4)
C(45)
11680(20)
6515(17)
4683(8)
151(8)
C(46)
13180(20)
5980(20)
4734(7)
173(10)
N(1)
829(13)
9016(8)
642(4)
68(3)
N(2)
−535(12)
8485(8)
885(4)
68(3)
N(3)
3041(12)
9614(8)
960(4)
68(3)
N(4)
6055(13)
10721(8)
539(4)
69(3)
N(5)
7701(12)
11158(8)
1162(4)
66(3)
N(6)
3572(11)
9644(7)
1926(4)
69(3)
N(7)
4266(13)
9733(9)
2867(4)
80(3)
N(8)
6627(16)
9463(12)
4010(4)
87(3)
N(9)
5834(12)
4018(8)
649(4)
67(3)
N(10)
4481(11)
3519(8)
912(5)
65(3)
N(11)
8121(11)
4589(8)
947(4)
64(3)
N(12)
11105(12)
5736(8)
531(4)
64(3)
N(13)
12752(11)
6231(7)
1136(4)
60(3)
N(14)
8709(10)
4590(8)
1900(4)
62(3)
N(15)
9458(12)
4729(9)
2854(4)
76(3)
N(16)
12019(15)
5101(9)
3959(4)
78(3)
O(1)
4632(15)
10623(9)
3999(4)
123(4)
O(2)
9488(12)
5219(10)
4012(4)
115(4)
[0059] In a still different embodiment, the T1H1.5-4 Form of Compound I is characterized by a powder x-ray diffraction pattern substantially in accordance with that shown in FIG. 1 .
[0060] In a further embodiment, the T1H1.5-4 Form of Compound I is characterized by a differential scanning calorimetry thermogram substantially in accordance with that shown in FIG. 2 . The T1H1.5-4 Form may be characterized by a melting point in the range of about 267° C. to about 271° C.
[0061] In a still further embodiment, the T1H1.5-4 Form of Compound I is characterized by a powder x-ray diffraction pattern (CuKαλ=1.5418 Å) comprising four or more 2θ values, preferably comprising five or more 2θ values, selected from the group consisting of: 3.9±0.2, 12.7±0.2, 13.8±0.2, 14.7±0.2, 15.6±0.2, 18.8±0.2, 25.4±0.2, 26.1±0.2 and 26.9±0.2, at room temperature.
[0062] In another embodiment, the T1H1.5-4 Form is in substantially pure form. This crystalline form of Compound I in substantially pure form may be employed in pharmaceutical compositions which may optionally include one or more other components selected, for example, from excipients and carriers; and optionally, one or more other active pharmaceutical ingredients having active chemical entities of different molecular structures.
[0063] Preferably, the T1H1.5-4 crystalline form has substantially pure phase homogeneity as indicated by less than 10%, preferably less than 5%, and more preferably less than 2% of the total peak area in the experimentally measured powder x-ray diffraction (PXRD) pattern arising from the extra peaks that are absent from the simulated PXRD pattern. Most preferred is a crystalline form having substantially pure phase homogeneity with less than 1% of the total peak area in the experimentally measured PXRD pattern arising from the extra peaks that are absent from the simulated PXRD pattern.
[0064] In one embodiment, the T1H1.5-4 Form is in substantially pure form, wherein substantially pure is greater than 90 weight % pure, preferably greater than 95 weight % pure, and more preferably greater than 99 weight % pure.
[0065] In a different embodiment, a composition is provided consisting essentially of the crystalline Form T1H1.5-4 of Compound I. The composition of this embodiment may comprise at least 90 weight %, preferably at least 95 weight %, and more preferably at least 99 weight % of the crystalline Form T1H1.5-4 of Compound I, based on the weight of Compound I in the composition.
[0066] In yet another embodiment, the T1H1.5-4 crystalline form of Compound I may be characterized by a thermogravimetric analysis (TGA) thermogram having minimal weight loss in accordance to a sesquihydrate form. The invention also provides Form T1H1.5-4 crystal that exhibits a TGA thermogram substantially the same as shown in FIG. 3 .
[0067] The present invention also provides a pharmaceutical composition comprising a crystalline form of Compound I, wherein Compound I is in Form T1H1.5-4; and a pharmaceutically acceptable carrier or diluent. The pharmaceutical composition may comprise the Form T1H1.5-4 in substantially pure form.
[0068] In one embodiment, an oral dosage form is provided comprising Compound I wherein Compound I is in a crystalline form comprising Form T1H1.5-4. The oral dosage form may comprise Compound I wherein Compound I consists essentially of Form T1H1.5-4. Alternatively, the oral dosage form may comprise Compound I wherein Compound I is in substantially pure form. A suitable amount of Compound I in the oral dosage form is, for example, in the range of from about 1 to 500 mg.
[0069] The present invention further provides a method for treating a proliferative disease, comprising administering to a mammalian species in need thereof, a therapeutically effective amount of Compound I, wherein Compound I is provided in a crystalline form comprising Form T1H1.5-4. Preferably, Compound I consists essentially of Form T1H1.5-4. Preferably, the mammalian species is human.
[0070] Compound I in Form T1H1.5-4 may be formulated with a pharmaceutical vehicle or diluent for oral, intravenous, or subcutaneous administration. The pharmaceutical composition can be formulated in a classical manner using solid or liquid vehicles, diluents, and/or additives appropriate to the desired mode of administration. Orally, Form T1H1.5-4 of Compound I can be administered in the form of tablets, capsules, granules, powders, and the like. Crystalline Form T1H1.5-4 of Compound I may also be administered as a suspension using carriers appropriate to this mode of administration.
[0071] The effective amount of Compound I may be determined by one of ordinary skill in the art, and includes exemplary dosage amounts for a mammal of from about 0.05 to about 300 mg/kg/day, preferably less than about 200 mg/kg/day, in a single dose or in 2 to 4 divided doses. It will be understood that the specific dose level and frequency of dosage for any particular subject may be varied and will depend upon a variety of factors, the bioavailability of Compound I in Form T1H1.5-4, the metabolic stability and length of action of Compound I, the species, age, body weight, general health, sex, and diet of the subject, the mode and time of administration, rate of excretion, drug combination, and severity of the particular condition. Preferred subjects for treatment include animals, most preferably mammalian species such as humans and domestic animals such as dogs, cats, horses, and the like.
[0072] Exemplary compositions for oral administration include suspensions comprising particles of Compound I in Form T1H1.5-4 dispersed in a liquid medium. The suspension may further comprise, for example, microcrystalline cellulose for imparting bulk, alginic acid or sodium alginate as a suspending agent, methylcellulose as a viscosity enhancer, and sweeteners or flavoring agents such as those known in the art; and immediate release tablets which may contain, for example, microcrystalline cellulose, dicalcium phosphate, starch, magnesium stearate, and/or lactose and/or other excipients, binders, extenders, disintegrants, diluents, and lubricants such as those known in the art. Compound I in Form T1H1.5-4 also may be delivered by sublingual and/or buccal administration, e.g. with molded, compressed, or freeze-dried tablets. Exemplary compositions may include fast-dissolving diluents such as mannitol, lactose, sucrose, and/or cyclodextrins. Also, included in such formulations may be high molecular weight excipients such as celluloses (AVICEL®) or polyethylene glycols (PEG); an excipient to aid mucosal adhesion such as hydroxypropyl cellulose (HPC), hydroxypropyl methyl cellulose (HPMC), sodium carboxymethyl cellulose (SCMC), and/or maleic anhydride copolymer (e.g., GANTREZ®); and agents to control release such as polyacrylic copolymer (CARBOPOL)934®). Lubricants, glidants, flavors, coloring agents, and stabilizers may also be added for ease of fabrication and use.
[0073] An example of a composition for oral administration is Compound I in crystalline Form T1H1.5-4, lactose monohydrate (intra-granular phase), microcrystalline cellulose (intra-granular phase), croscarmellose sodium (intra-granular phase), hydroxypropyl cellulose (intra-granular phase), microcrystalline cellulose (extra-granular phase), croscarmellose sodium (extra-granular phase), and magnesium stearate (extragranular phase).
[0074] Typically, the solid form of a pharmaceutically active material is important in the preparation of a solid dosage form, such as tablets or capsules as the manufacturing, stability, and/or the performance of the pharmaceutically active material can be dependent upon the solid form. Generally, a crystalline form provides pharmaceutically active material with uniform properties, such as solubility, density, dissolution rate, and stability. In the present invention, Compound I in the crystalline Form T1H1.5-4 has properties suitable for the manufacture of tablets or capsules, for providing a stable oral dosage form, and/or for delivery of Compound I to a patient in need thereof.
Methods of Preparation and Characterization
[0075] Crystalline forms may be prepared by a variety of methods, including for example, crystallization or recrystallization from a suitable solvent, sublimation, growth from a melt, solid state transformation from another phase, crystallization from a supercritical fluid, and jet spraying. Techniques for crystallization or recrystallization of crystalline forms from a solvent mixture include, for example, evaporation of the solvent, decreasing the temperature of the solvent mixture, crystal seeding a supersaturated solvent mixture of the molecule and/or salt, freeze drying the solvent mixture, and addition of antisolvents (countersolvents) to the solvent mixture. High throughput crystallization techniques may be employed to prepare crystalline forms including polymorphs.
[0076] Crystals of drugs, including polymorphs, methods of preparation, and characterization of drug crystals are discussed in Solid - State Chemistry of Drugs , S. R. Byrn, R. R. Pfeiffer, and J. G. Stowell, 2 nd Edition, SSCI, West Lafayette, Ind. (1999).
[0077] For crystallization techniques that employ solvent, the choice of solvent or solvents is typically dependent upon one or more factors, such as solubility of the compound, crystallization technique, and vapor pressure of the solvent. Combinations of solvents may be employed, for example, the compound may be solubilized into a first solvent to afford a solution, followed by the addition of an antisolvent to decrease the solubility of the compound in the solution and to afford the formation of crystals. An antisolvent is a solvent in which the compound has low solubility.
[0078] In one method to prepare crystals, a compound is suspended and/or stirred in a suitable solvent to afford a slurry, which may be heated to promote dissolution. The term “slurry”, as used herein, means a saturated solution of the compound, which may also contain an additional amount of the compound to afford a heterogeneous mixture of the compound and a solvent at a given temperature.
[0079] Seed crystals may be added to any crystallization mixture to promote crystallization. Seeding may be employed to control growth of a particular polymorph or to control the particle size distribution of the crystalline product. Accordingly, calculation of the amount of seeds needed depends on the size of the seed available and the desired size of an average product particle as described, for example, in “Programmed Cooling of Batch Crystallizers,” J. W. Mullin and J. Nyvlt, Chemical Engineering Science, 1971, 26, pp. 369-377. In general, seeds of small size are needed to control effectively the growth of crystals in the batch. Seed of small size may be generated by sieving, milling, or micronizing of large crystals, or by micro-crystallization of solutions. Care should be taken that milling or micronizing of crystals does not result in any change in crystallinity from the desired crystal form (i.e., change to amorphous or to another polymorph).
[0080] A cooled crystallization mixture may be filtered under vacuum, and the isolated solids may be washed with a suitable solvent, such as cold recrystallization solvent, and dried under a nitrogen purge to afford the desired crystalline form. The isolated solids may be analyzed by a suitable spectroscopic or analytical technique, such as solid state nuclear magnetic resonance, differential scanning calorimetry, powder x-ray diffraction, or the like, to assure formation of the preferred crystalline form of the product. The resulting crystalline form may be produced in an amount of greater than about 70 weight % isolated yield, preferably greater than 90 weight % isolated yield, based on the weight of the compound originally employed in the crystallization procedure. The product may be co milled or passed through a mesh screen to delump the product, if necessary.
[0081] Crystalline forms may be prepared directly from the reaction medium of the final process for preparing Compound I. This may be achieved, for example, by employing in the final process step a solvent or a mixture of solvents from which
[0082] Compound I may be crystallized. Alternatively, crystalline forms may be obtained by distillation or solvent addition techniques. Suitable solvents for this purpose include, for example, the aforementioned nonpolar solvents and polar solvents, including protic polar solvents such as alcohols, and aprotic polar solvents such as ketones.
[0083] The presence of more than one crystalline form and/or polymorph in a sample may be determined by techniques such as powder x-ray diffraction (PXRD) or solid state nuclear magnetic resonance spectroscopy. For example, the presence of extra peaks in the comparison of an experimentally measured PXRD pattern with a simulated PXRD pattern may indicate more than one crystalline form and/or polymorph in the sample. The simulated PXRD may be calculated from single crystal x-ray data. see Smith, D. K., “A FORTRAN Program for Calculating X-Ray Powder Diffraction Patterns,” Lawrence Radiation Laboratory, Livermore, Calif., UCRL-7196 (April 1963).
[0084] Form T1H1.5-4 of Compound I according to the invention may be characterized using various techniques, the operations of which are well known to those of ordinary skill in the art. Form T1H1.5-4 of Compound I may be characterized and distinguished using single crystal x-ray diffraction performed under standardized operating conditions and temperatures, which is based on unit cell measurements of a single crystal of the form at a fixed analytical temperature. The approximate unit cell dimensions in Angstroms (Å), as well as the crystalline cell volume, spatial grouping, molecules per cell, and crystal density may be measured, for example at a sample temperature of 25° C. A detailed description of unit cells is provided in Stout & Jensen, X-Ray Structure Determination: A Practical Guide, Macmillan Co., New York (1968), Chapter 3, which is herein incorporated by reference.
[0085] Alternatively, the unique arrangement of atoms in spatial relation within the crystalline lattice may be characterized according to the observed fractional atomic coordinates. Another means of characterizing the crystalline structure is by powder x-ray diffraction analysis in which the diffraction profile is compared to a simulated profile representing pure powder material, both run at the same analytical temperature, and measurements for the subject form characterized as a series of 2θ values (usually four or more).
[0086] Other means of characterizing the form may be used, such as solid state nuclear magnetic resonance (NMR), differential scanning calorimetry, thermography, and gross examination of the crystalline or amorphous morphology. These parameters may also be used in combination to characterize the subject form.
[0087] The crystalline form was analyzed using one or more of the testing methods described below.
Single Crystal X-Ray Measurement
[0088] Single crystal X-ray data were collected on a Bruker AXS APEX II diffractometer with MicroStarH generator using CuKα radiation (λ=1.5418 Å). Indexing and processing of the measured X-ray intensity data were carried out with the APEX2 software suite (Bruker AXS, Inc., Madison, Wis., USA). The structure was solved by direct methods and refined on the basis of observed reflections using SHELXTL crystallographic package (Bruker AXS, Inc., Madison, Wis., USA). The derived atomic parameters (coordinates and temperature factors) were refined through full matrix least-squares. The function minimized in the refinements was Σ w (|F o |−|F c |) 2 . R is defined as Σ∥F o |−|F c ∥/Σ|F o |, while R w =[Σ w (|F o |−|F c |) 2 /Σ w |F o | 2 ] 1/2 , where w is an appropriate weighting function based on errors in the observed intensities. All non-hydrogen atoms were refined with anisotropic thermal displacement parameters. Hydrogen atoms were calculated from an idealized geometry with standard bond lengths and angles and refined using a riding model.
DSC (Open Pan)
[0089] DSC experiments were performed in a TA INSTRUMENTS® model Q2000 or Q1000. The sample (about 2-10 mg) was weighed into an aluminum pan and the weight recorded accurately to a hundredth of a milligram, and transferred to the DSC.
[0090] The instrument was purged with nitrogen gas at 50 mL/min. Data were collected between room temperature and 300° C. at a heating rate of 10° C./min. The plot was made such that endothermic peaks point down.
TGA (Open Pan)
[0091] TGA experiments were performed in a TA INSTRUMENTS® model Q5000 or Q500. The sample (about 4-30 mg) was placed in a previously tared platinum pan. The weight of the sample was measured accurately and recorded to a thousandth of a milligram by the instrument. The furnace was purged with nitrogen gas at 100 mL/min. Data were collected between room temperature and 300° C. at a heating rate of 10° C./min.
PXRD
[0092] PXRD data were obtained using a Bruker C2 GADDS. The radiation was CuKα (40 KV, 40 mA). The sample-detector distance was 15 cm. Powder samples were placed in sealed glass capillaries of 1 mm or less in diameter; the capillary was rotated during data collection. Data were collected approximately for 2≦2θ≦35° with a sample exposure time of at least 1000 seconds. The resulting two-dimensional diffraction arcs were integrated to create a traditional 1-dimensional PXRD pattern with a step size of 0.05 degrees 2θ in the approximate range of 2 to 32 degrees 2θ.
EXAMPLES
[0093] The invention is further defined in the following Examples. It should be understood that the Examples are given by way of illustration only. From the above discussion and the Examples, one skilled in the art can ascertain the essential characteristics of the invention, and without departing from the spirit and scope thereof, can make various changes and modifications to adapt the invention to various uses and conditions. As a result, the invention is not limited by the illustrative examples set forth below, but rather is defined by the claims appended hereto.
Example 1
Preparation of Form T1H1.5-4 of Compound I
[0094] Crystal form T1H1.5-4 (neat), was obtained when Crystal form H1.5-4 (sesquihydrate) underwent dehydration upon heating at 40° C.
[0095] Crystal form H1.5-4 (sesquihydrate) was prepared by adding 6 mg of Compound I (crystalline free base) to a mixture of dimethylformamide (0.35 ml), water (0.35 ml) and 1.2 equivalents of sulfuric acid . Colorless plate-shaped crystals of H1.5-4 were obtained after two days of slow evaporation of solution at room temperature.
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Crystalline form, Form T1H1.5-4, of N,N-dicyclopropyl-4-(1,5-dimethyl-1H-pyrazol-3-ylamino)-6-ethyl-1-methyl -1,6-dihydroimidazo[4,5-d]pyrrolo[2,3-b]pyridine-7-carboxamide (Compound (I)) is provided. Also provided is a pharmaceutical composition and an oral dosage form comprising Form T1H1.5-4 of Compound (I) as well as a method of using the Form T1H1.5-4 of Compound for the treatment of myeloproliferative disorders, which include polycythaemia vera, thrombocythaemia and primary myelofibrosis.
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This application is a continuation of U.S. patent application Ser. No. 08/576,952 filed Dec. 22, 1995, abandoned.
FIELD OF THE INVENTION
The invention relates generally to thin film integrated circuit design and fabrication. In particular, the invention pertains to electrode design and materials used in stacked cell capacitor Dynamic Random Access Memories (DRAM).
BACKGROUND OF THE INVENTION
A dynamic random access memory (DRAM) cell typically comprises a charge storage capacitor (or cell capacitor) coupled to an access device such as a Metal-Oxide-Semiconductor Field Effect Transistor (MOSFET). The MOSFET functions to apply or remove charge on the capacitor, thus affecting a logical state defined by the stored charge. The amount of charge stored on the capacitor is determined by the capacitance, C=εA/d, where ε is the dielectric constant of the capacitor dielectric, A is the electrode (or storage node) area and d is the interelectrode spacing. The conditions of DRAM operation such as operating voltage, leakage rate and refresh rate, will in general mandate that a certain minimum charge be stored by the capacitor.
In the continuing trend to higher memory capacity, the packing density of storage cells must increase, yet each will maintain required capacitance levels. This is a crucial demand of DRAM fabrication technologies if future generations of expanded memory array devices are to be successfully manufactured. Nevertheless, in the trend to higher memory capacity, the packing density of cell capacitors has increased at the expense of available cell area. For example, the area allowed for a single cell in a 64-Mbit DRAM is only about 1.4 μm 2 . In such limited areas, it is difficult to provide sufficient capacitance using conventional stacked capacitor structures. Yet, design and operational parameters determine the minimum charge required for reliable operation of the memory cell despite decreasing cell area. Several techniques have been developed to increase the total charge capacity of the cell capacitor without significantly affecting the cell area. These include new structures utilizing trench and stacked capacitors, electrodes having textured surface morphology and new capacitor dielectric materials having higher dielectric constants.
Recently, for example, a great deal of attention has been given to the development of thin film dielectric materials that possess a dielectric constant significantly greater (>10×) than the conventional dielectrics used today, such as silicon oxides or nitrides. Particular attention has been paid to Barium Strontium Titanate (BST), Barium Titanate (BT), Lead Zirconate Titanate (PZT), Tantalum Pentoxide (Ta 2 O 5 ) and other high dielectric constant materials as a cell dielectric material of choice for DRAMs. These materials, in particular BST, have a high dielectric constant (>300) and low leakage currents which makes them very attractive for high density memory devices. Due to their reactivity and complex processing, these dielectric materials are generally not compatible with the usual polysilicon electrodes. Thus, much effort has been directed to developing suitable metal electrodes for use with such dielectric materials.
As DRAM density has increased (1 MEG and beyond), thin film capacitors, such as stacked capacitors (STC), trenched capacitors, or combinations thereof, have evolved in attempts to meet minimum space requirements. Many of these designs have become elaborate and difficult to fabricate consistently as well as efficiently. Furthermore, the recent generations of DRAMs (4 MEG, 16 MEG for example) have pushed conventional thin film capacitor technology to the limit of processing capability. In giga-scale STC DRAMs the electrode conductivity plays an important role in device size and performance; thus, two kinds of capacitors have been considered, the three-dimensional metal electrode such as the FIN or CROWN, or the simple metal electrode with higher-permitivity dielectric films. For example, a recent article by T. Kaga et al. ("0.29 μm 2 MIM-CROWN Cell and Process Technologies for 1-Gigabit DRAMs," T. Kaga et al., IEDM '94, pp. 927-929.) discloses a substituted tungsten process for forming three-dimensional metal electrodes from polysilicon "molds." The article, herein incorporated by reference, discloses a method advantageous for creating metal structures, such as capacitor electrodes; nevertheless the simple structures created thus far are not sufficient to meet the demands of giga-scale DRAM arrays.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a metal structure having a textured surface morphology. It is another object of the present invention to provide processes by which textured metal structures are fabricated, such processes being compatible with silicon integration technology. It is furthermore an object of the present invention to provide a metal-insulator-metal DRAM capacitor having textured electrodes advantageous for gigabit-scale memory arrays.
In accordance with one aspect of the present invention a method of forming a textured metal structure comprises first forming a predetermined textured silicon structure having the desired form, and then replacing silicon atoms in the textured structure with metal atoms. A method of forming a predetermined textured structure preferably comprises depositing an amorphous or polycrystalline silicon structure by chemical vapor deposition, and then exposing the structure to a controlled annealing process to form a silicon surface having a textured surface morphology. The metal substitution process preferably comprises exposing the textured structure to a refractory metal-halide complex, and most preferably to WF 6 .
In accordance with another aspect of the present invention, a process for fabricating a metal-insulator-metal capacitor on a semiconductor wafer comprises first forming a silicon electrode structure on the semiconductor wafer, texturizing the silicon electrode structure, and then replacing the silicon in the silicon electrode structure with a metal, thereby forming a textured metal electrode. The process further comprises depositing a dielectric layer having a high dielectric constant over the textured metal electrode followed by a metal layer deposited over the dielectric layer. Replacing the silicon in the silicon electrode structure preferably comprises exposing the silicon electrode structure to a refractory metal-halide complex, such as WF 6 . The dielectric layer preferably comprises a material selected from the group consisting of Ta 2 O 5 , BaTiO 3 , SrTiO 3 , Ba x Sr 1-x ,TiO 3 , and PbZr x Ti 1-x O 3 , and the metal layer preferably comprises titanium.
In accordance with yet another aspect of the present invention a DRAM capacitor comprises a metal electrode having a textured surface morphology overlayed by a dielectric material having a high dielectric constant and covered by a metal layer. The metal electrode of the DRAM capacitor is preferably comprised of a refractory metal, such as tungsten. The dielectric material of the DRAM capacitor is preferably comprised of a material selected from the group consisting of Ta 2 O 5 , BaTiO 3 , SrTiO 3 , Ba x Sr 1-x TiO 3 , and PbZr x Ti 1-x O 3 . Furthermore, the top electrode layer of the DRAM capacitor preferably comprises a refractory metal, such as titanium.
These and other objects and attributes of the present invention will become more fully apparent with the following detailed description and accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic section of an exemplary DRAM structure having textured electrodes.
FIG. 2 is a schematic section of the DRAM structure shown in FIG. 1 illustrating a completed oxide "mold."
FIG. 3 is a tic section of a preferred DRAM electrode after a metal substitution process.
FIG. 4 is a schematic section of a preferred DRAM electrode after oxide removal.
FIG. 5 is a schematic section of a preferred DRAM electrode with a deposited dielectric layer.
FIG. 6 is a schematic section of a completed DRAM structure in accordance with the present invention.
FIG. 7 is a schematic section of an alternative embodiment of a completed DRAM structure in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the principles of the present invention, complex metal structures having enhanced surface area advantageous for DRAM storage capacitors are fabricated by first forming rugged or texturized polysilicon ("poly") electrodes and subsequently subjecting the poly structures to a metal-substitution process. The rugged metal electrodes are advantageous for high-density DRAM storage applications because they exhibit a substantially higher conductivity than conventional doped poly electrodes and they are compatible with high-ε dielectric materials such as Ta 2 O 5 , BST, PZT and others. The preferred embodiment of the present invention is directed to a novel DRAM storage cell having a rugged metal electrode. The inventive aspects are herein disclosed in connection with a preferred process for fabricating rugged metal electrodes in accordance with the aforementioned principles, beginning with the formation of the cell capacitor itself.
Referring to FIG. 1, a conventional front-end DRAM cell formation comprises a semiconductor substrate 12 processed to a point where capacitor fabrication begins. At this stage in the fabrication process, the DRAM cell may have field oxide regions 16, active regions 14, word lines 18, bit lines 20, capacitor plugs 22, and planarizing layer 23. The capacitor structures of the present invention begins with the formation of polysilicon electrodes 24 having a textured or rugged surface region 26. The textured surface 26 increases the electrode surface area without increasing the lateral dimensions of the electrode 24.
Polysilicon or amorphous silicon (a-Si) are preferred materials from which to fabricate the electrode structure 24 and rugged surface 26. The subsequent metal substitution reaction (to be described) is shown to be effective in faithfully replicating the silicon structure by the substituted metal. Moreover, such reactions are compatable with other silicon fabrication processes and thus are capable of producing complex structures with high dimensional tolerances in a cost-effective manner. For example, the silicon electrodes 24 may be formed by depositing a layer of polysilicon or a-Si over the poly plugs 22 and adjacent oxide spacers 28 by well-known chemical vapor deposition processes. A subsequent planarizing process such as a chemical-mechanical polish or anisotropic etch may remove the topmost portion of the layer, yielding the isolated electrode structures 24. The rugged surface 26 may be fabricated by a seeding and anneal process which produces a rough surface morphology comprising relatively large polycrystalline silicon grains of about 50-200 nm. Such processes for example are disclosed in U.S. Pat. No. 5,102,832 by M. E. Tuttle, herein incorporated by reference. A seeding process may for example comprise dispersing a material such as polysilicon or silicon dioxide over the surface which produces nucleation sites on the surface of the silicon electrodes 24. A controlled anneal process then induces accumulation of silicon at the nucleation sites, thereby forming a rough surface morphology having enhanced surface area. The resulting surface morphology, often appearing bulbous, is usually comprised of relatively large polycrystallites, referred to as Hemispherically Grained Silicon (HSG). An exemplary method for forming HSG on complex stacked capacitor structures is disclosed in U.S. Pat. No. 5,340,765 by C. H. Dennison et al., also herein incorporated by reference. It will be appreciated that the processes heretofore disclosed are sufficient to produce a starting electrode structure 24 having a rugged surface 26 in accordance with the present invention. However, the processes themselves are disclosed by way of example, and it will also be appreciated that other processes may be utilized to achieve a similar result.
Beginning with the complex electrode structure shown in FIG. 1, and referring now to FIG. 2, a next step in accordance with the present embodiment comprises depositing a silicon dioxide ("oxide") layer over the entire structure and planarizing to produce the filled oxide regions 30. The oxide layer 28 and filled oxide regions 30 thus form a boundary or "mold" between which the metal substitution process shall proceed.
The next step in the present embodiment is to convert the silicon electrode structure 24 with ruggedized surface 26 to a metal electrode by the general process:
aM.sub.x R.sub.y +bSi→axM+bSiR.sub.aY/b
where M x R y is a refractory metal-halide complex such as WF 6 , and a, b are appropriate numerical constants. It is anticipated that a variety of refractory metal complexes may be used for the substitution, such as complexes of tungsten, molybdenum, and titanium. For example, the silicon comprising the electrode structures 10, may be converted to tungsten (W) by the process:
2WF.sub.6 +3Si→2W+3SiF.sub.4
yielding electrodes 32 having rugged surfaces 26 comprised of substantially tungsten metal, as shown in FIG. 3. The process may be carried out in situ by exposing the wafer to the volatile W complex. The time required for a substitution will in general depend upon other parameters such as the wafer temperature, W-complex partial pressure and volume of material to be substituted. For the general size of structures considered here, the metal substitution may require 10 or several tens of minutes. The process may be accelerated by a chemical-oxide pretreatment, for example comprising exposing the silicon electrode structures 10 to a mixture of ammonia (NH 3 ) and hydrogen peroxide (H 2 O 2 ) prior to the metal substitution process. The chemical oxide is shown to assist in the substitution process. In general, as shown in FIG. 3, the metal substitution results in a conversion of the electrode structures 10 into structures comprising substantially of the substituted metal. In the present embodiment, the structures 10 are comprised of substantially W. As shown in FIG. 4, the oxide regions 28 and 30 are removed by wet etching to expose the metal electrode structures to further processing.
An appropriate dielectric layer 34 is then deposited conformally over the metal electrode structures 10 as shown in FIG. 5. Preferred dielectric layers comprise materials having high dielectric constant ε, such as Ta 2 O 5 , BaTiO 3 , SrTiO 3 , Ba x Sr 1-x TiO 3 or PbZr x Ti 1-x O 3 . Such materials may be deposited by chemical vapor deposition processes, as is well-known in the art. The capacitor structure is completed by deposition of a reference electrode layer 36, preferably also by a CVD process. The reference electrode 36 should minimally comprise a material having high conductivity, and which is also chemically compatible with the dielectric layer 34. CVD titanium or TiN may for example serve as reference electrodes as they are compatible with titanate-based dielectrics.
As shown in FIG. 7, alternative embodiments of the complex, rugged metal electrodes may comprise textured surfaces 26 extending over the outer portions of the metal electrodes 38, thereby providing even greater capacitance. Clearly the principle of forming rugged metal electrodes may be extended to a variety of capacitor arrangements where good conductivity and high capacitance are requisite in small geometries.
Although described above with reference to the preferred embodiments, modifications within the scope of the invention may be apparent to those skilled in the art, all such modifications are intended to be within the scope of the appended claims.
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Thin film metal-insulator-metal capacitors having enhanced surface area are formed by a substituting metal for silicon in a preformed electrode geometry. The resulting metal structures are advantageous for high-density DRAM applications since they have good conductivity, enhanced surface area and are compatible with capacitor dielectric materials having high dielectric constant.
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FIELD OF THE INVENTION
The present invention relates to laser-assisted particle analysis and, more particularly, to laser-assisted spectrometry systems for analyzing particulate-laden gas streams.
BACKGROUND OF THE INVENTION
Particle detection and analysis is desirable in a variety of manufacturing and environmental contexts. For example, in clean rooms used for the fabrication of integrated circuits, highly accurate particle detection is required due to the small dimensions of the devices under production. Significant failure rates in integrated circuits are associated with the presence of particles greater than one-tenth the device linewidth. Typically, the smaller the size of the particle, the greater the number of particles which are present. Therefore, as linewidths decrease within the sub-micron range, particle removal becomes increasingly difficult and costly. Consequently, control of a particle source is usually more cost-effective than removal of particles once they are liberated from their source. Through real-time particle analysis, particle sources can be identified and controlled.
Particle detection and analysis in clean rooms and gas distribution systems is typically done by real-time, also known as on-line, counting of airborne particles followed by off-line analysis of deposited particles by microscopic or laser scan techniques. The former technique provides the rapid response required for monitoring particle generation events while the latter technique provides size and elemental composition information. Particle counting is frequently performed using standard light-scattering particle counters. However, these devices can only detect particles on the order of 50 nanometers or greater and provide no compositional information. While off-line analysis provides particle composition information, it is also limited by the particle sizes it can detect and cannot be time-correlated to particle generation events.
Mass spectrometry is an analytical technique used for the accurate determination of molecular weights, identification of chemical structures, determination of mixture compositions, and quantitative elemental analysis. Molecular structure is typically determined from the fragmentation pattern of ions formed when the molecule is ionized. Elemental content of molecules is determined from mass values obtained using mass spectrometers. However, since mass spectrometers typically operate in vacuum, particulate analysis usually requires that nearly all of the particulate carrier be separated from the particulate material prior to ionization in the spectrometer. This requirement increases the complexity of particle detection for particulates suspended in liquids and gases.
Real-time or on-line particle analysis for particles suspended in gases is normally accomplished by sampling particles through a differentially pumped nozzle and impacting the particle beam onto a heated surface. In this manner, impinging particles are ionized and analyzed. However, this surface ionization technique results in the creation of ions from both the particle beam and the surface being heated, making it difficult to determine the composition and size of the particles of interest. Additionally, not all elements of the particulate sample will form ions, resulting in discrimination against certain elements, typically those elements with high electronegativities and high ionization potentials.
More universal detection can be achieved through electron impact ionization of neutral species ejected by the collision of a particle beam with a heated surface. However, this method creates extensive fragmentation and results in lower ionization yields than surface ionization. Scanning mass analyzers, such as the quadrapole or magnetic sector analyzers can also be used for particulate analysis. Due to the transient nature of the signal produced in these devices, it is difficult or impossible to obtain a complete mass spectrum. As a result, these analyzers show poor sensitivity and difficulty in performing multicomponent determinations.
Many of the difficulties associated with the above techniques can be reduced or eliminated through the use of a laser-induced mass spectrometry system taught in U.S. Pat. No. 5,382,794 issued Jan. 17, 1995, commonly assigned to the instant assignee, the disclosure of which is incorporated by reference herein. In the patent, an exemplary laser-induced mass spectrometry system is described in which particles enter an evacuable chamber through an inlet device such as a capillary. A laser, such as a pulsed laser, is positioned such that the laser beam intersects the particle stream. As the particles pass through the path of the laser beam, they are fragmented and ionized. A detector, such as a time-of-flight mass spectrometer detects the ionized species. Mass spectra are produced, typically being recorded with an oscilloscope, and analyzed with a microprocessor. The mass spectra information permits real-time analysis of the particle size and composition.
While the laser-assisted spectrometry system described in the patent provides useful real-time particulate analysis, there is a continuing need to provide compositional and size evaluation for increasingly smaller particulates. There is a further need in the art for detection and analysis of a greater percentage of the particulate contents of a sample, to ensure accurate characterization. Finally, there is a need in the art for particulate analysis systems and techniques which do not discriminate against high electronegativity and high ionization potential elements.
SUMMARY OF THE INVENTION
The present invention provides methods and apparatus for analyzing the particulate contents of a sample such that a high proportion of the sample particles are analyzed without discrimination against high electronegativity and high ionization potential elements. In an exemplary embodiment, the invention comprises an apparatus for analyzing the particulate content of a sample having particulate diameters in a range of 0.001-10 microns. The apparatus comprises an evacuable chamber equipped with a chamber entrance through which a particle-laden gas stream enters. An inlet device, such as a capillary, communicates with the chamber entrance for inputting the particle-laden gas stream to the evacuable chamber. A laser is positioned to produce a focused laser beam which intersects the particle-laden gas stream at a position approximately 0.05 mm to 1.0 mm from the chamber entrance. The laser beam has a power density sufficient to fragment and ionize particles entrained within the particle-laden gas stream. A detector is positioned to detect the ionized species produced by the laser.
In an exemplary embodiment, the capillary dimensions are selected such that the gas flow is less than approximately 2 milliliters/second and the laser beam has a high power density, typically greater than 10 11 W/cm 2 . These conditions help ensure accurate detection of a large percentage of the particles entrained in a gas stream, typically on the order of 1 in 100 particles.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically depicts a laser particle analyzer in partial cross-section according to one embodiment of the present invention.
FIG. 2 schematically depicts the particle dispersion from a particle-laden gas stream exiting a capillary.
DETAILED DESCRIPTION
Referring now to the drawings in detail in which like numerals indicate the same or similar elements in view, FIG. 1 depicts a particle analyzer 20 according to the present invention. The apparatus 20 incudes an inlet device 30 through which particles enter a differentially pumped chamber 60. Chamber 60 is generally maintained at a pressure of at least approximately 10 -3 torr by a vacuum pumping system 70. Pumping system 70 is selected from any device capable of maintaining vacuum in the desired range, including, but not limited to, mechanical pumps, diffusion pumps, cryogenic pumps, turbomolecular pumps, and combinations thereof.
Inlet device 30 includes capillary 50 fabricated from materials which provide a smooth interior surface, such as fused silica. Typically, the inner diameter of inlet device 30 is on the order of 0.20 to 0.53 mm with a length of approximately 0.1 to 10 meters for particle analysis in the submicron range. The use of an inlet capillary of these dimensions assists in collimating the particle-laden gas stream and advantageously eliminates the need for mechanical pumping along the path of the capillary. Further, the small capillary size greatly reduces the velocity of the particle-laden gas stream. As a result of the slower gas stream speed, there is a higher probability that a given particle will reside in a laser spot during a laser pulse; resulting in a higher percentage of particles being analyzed. The volume of particle-laden gas flow is typically less than about 2 milliliters/second. The reduced gas stream velocity also reduces the gas load on the pumping system for chamber 60, permitting use of smaller pumping systems or using pumping system 70 for plural pumping functions.
To ionize the particles injected through capillary 50, a laser 10 is positioned such that the focused laser beam passes through an opening in chamber 60 and intersects the particle-laden gas stream adjacent chamber entrance 62. In a preferred embodiment, the edge of the beam spot is positioned on the order 0.05-1.0 mm from the chamber entrance. In an exemplary embodiment, the beam edge is positioned 0.1 mm from the chamber entrance. As depicted in FIG. 2, the particle-laden gas stream 90 begins to disperse immediately upon entering chamber 90. As a result of this dispersion, the further away from chamber entrance 62 that the laser beam 12 intersects particle-laden gas stream 90, the smaller is the subtended angle of the dispersion. Further, smaller particles are more easily carried by the expanding gas to a larger radius, while larger particles, e.g., particles greater than one micron, are concentrated in the center of the particle stream. As a result, positioning the focal point of the laser beam beyond the chamber entrance will tend to discriminate more heavily against analysis of smaller sized particulates. Consequently, a smaller percentage of the total number of particulates is ionized and analyzed for laser/gas stream intersection at any appreciable distance beyond chamber entrance 62. For the described configuration of the FIG. 1 analyzer, approximately 1 out of every 100 particles is analyzed.
In one embodiment, the desired spatial relationship among capillary 50, chamber entrance 62, and laser beam 12, is created through use of a precision x-y-z manipulator (not shown). It is emphasized that use of an x-y-z manipulator is illustrative. Any arrangement, adjustable, or fixed, which ensures the proper spatial relationship among these components can be used with the particle analyzers of the present invention. Capillary 50 is positioned within the manipulator and set to the desired distance from the laser beam.
The vibrations of the capillary are damped by an external fixed arm (not shown) so that the position of the capillary with respect to the laser beam can be maintained despite vibrations. The vibration damping element is a fixed arm which extends in one of the perpendicular directions
Laser 10 is selected from pulsed lasers having a short pulse width, a high peak power, a moderate spot size, and a high repetition rate. For the embodiment shown in FIG. 1, laser 10 has a pulse frequency in the range of 10 Hz to 10 kHz with a frequency of from 1 to 10 kHz being exemplary. The laser power is at least approximately 0.5 mJ with a power density on the order of at least 1.0×10 11 W/cm 2 with power densities of greater than 1.0×10 12 W/cm 2 , and, more particularly, greater than 1.0×10 13 W/cm 2 , being exemplary. Laser spot sizes are determined by the selected laser power and power density. Typically, laser spot sizes range between 0.001 to 20 mm 2 .
The use of high laser power densities ensures the ability to fully characterize the particle-laden gas stream. High laser power densities ensure ionization of high ionization potential elements. Additionally, smaller particles, which are more difficult to ionize since they transfer heat more efficiently than larger particles, ionize more readily at the higher laser power densities used in the present invention. Acceptable commercially-available lasers include a Lambda Physik excimer laser, model EMG 202, and a Spectra Physics DCR II Neodymium YAG laser.
Upon introduction of the particle-laden gas stream 90 into capillary 50, laser 10 is turned on and continuously fired. As the particle-laden gas stream enters chamber 60, it passes through the laser beam. The laser beam fragments a particle and ionizes the fragments, forming a plasma. For the high power densities of the present invention, the particle fragments yield positive ions.
A time-of-flight mass spectrometer (TOF/MS) 120, particularly a time-of-flight mass spectrometer including a reflectron, obtains the mass spectra ed by particles ionized by laser 10. While a time-of-flight mass spectrometer is depicted in FIG. 1, it is understood that this spectrometer is illustrative. A variety of mass spectrometers can be employed in the particle analyzers of the present invention including, but not limited to, quadrapole, magnetic sector, and quadrapole ion trap spectrometers, and Penning ion trap spectrometers such as FTICR spectrometers. Time-of-flight mass spectrometer 120 is a positive time-of-flight mass spectrometer. Pump system communicates with the spectrometer to maintain a pressure of less than approximately 10 -4 torr. Optionally, pump system 130 is combined with pump system 70 through a plural port system, reducing the number of pumping elements and hence the overall size and cost of the system.
Due to the high laser power densities employed in the present invention, the ionized particle fragments in the plasma are positive species The spectrometer counts each fragmentation incident and measures the masses and yields of the positive ions produced when the particle contacts the laser beam. The mass of the ions correlates to the travel time required for the ionized particle fragment to contact the mass spectrometer. A Jordan Associates dual time-of-flight mass spectrometer can be employed as spectrometer 12. Optionally, a positively charged grid (not shown) is positioned opposite spectrometer 120 to accelerate the positively charged ions toward the spectrometer.
Information from the spectrometer is transmitted to recording portion 200. In an exemplary embodiment, recording portion 200 comprises a transient recorder 160, such as a digital oscilloscope, which records the mass spectra. Processor 220, such as a computer, analyzes and displays the information received from oscilloscope 160. Optionally, the processor is itself included in recorder 160. It is understood that recording portion 200 is exemplary and that any device capable of recording, displaying, or otherwise processing information from spectrometer 120 is employable as element 200.
The apparatus and methods of the present invention are able to detect very small particles, such as those with a diameter of less than about 0.03 micron. These very small particles produce a small number of ions. This small number results in a low ion density which reduces ion spreading during their flight time. Reduced ion spreading significantly contributes to a reduction in the mass resolution of the time-of-flight mass spectrometer. The mass resolution relates to the width of the arrival time of ions with the same mass. Also, particle fragmentation and ionization time must be short; high laser power densities facilitate particle fragmentation and ionization in time periods less than the laser time width.
Ions from these very small particles produce pulse widths of less than 2 nanoseconds. For the above-described system, an ultrahigh mass resolution of greater than 30,000 at ion mass 180 is achieved. Currently, such resolutions are attained only by massive, costly, magnet-based mass spectrometers. The ability to achieve these resolutions with time-of-flight mass spectrometers represents a considerable cost and size reduction over prior art systems.
Advantageously, the laser-assisted particle analyzers of the present invention substantially completely fragment and ionize the incident particles due to high laser power density. In contrast, low power densities do not completely ionize fragments, so complete particle information is not obtained. By completely fragmenting and ionizing an incident particle, the ionized fragments yield an accurate representation of the parent particle. Consequently, ion measurements yield the amount of particular elements in the particle and the mass of material present in the particle can be directly determined from ion intensities. Other particle techniques typically determine a particle diameter and assume an ideal spherical shape. Mass is derived from the assumed shape using an estimated density. This approximation is especially poor for irregularly-shaped particles and those particles which are porous.
The present invention permits real-time detection and analysis of particles. Real-time analysis is particularly useful for evaluation of particles whose existence is transitory. For example, mechanical devices, when moved, generate a burst of particles for only a short time. Gas transport through a conduit can cause particles to be shed from inner surfaces, especially during pressure changes. Evaluating the composition of these particles, especially those smaller than 0.1 micron in diameter, is made possible through the apparatus and techniques of the present invention. Additionally the present invention is useful for the analysis of the particulate contents of liquid samples, as disclosed in copending U.S. patent application Ser. No. 08/373,731 filed concurrently herewith. and assigned to the instant assignee, the disclosure of which is incorporated by reference herein.
While the foregoing invention has been described in terms of the exemplary embodiments, it will be readily apparent that numerous modifications and changes can be made. Accordingly, modifications such as those suggested above, but not limited thereto, are considered to be within the scope of the claimed invention.
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The present invention provides methods and apparatus for analyzing the particulate contents of a sample such that a high proportion of the sample particles are analyzed without discrimination against high electronegativity and high ionization potential elements. In an exemplary embodiment, the invention comprises an apparatus for analyzing the particulate content of a sample having particulate diameters in range of 0.001-10 microns. The apparatus comprises an evacuable chamber equipped with a chamber entrance through which a particle-laden gas stream enters. An inlet device, such as a capillary, communicates with the chamber entrance for inputting the particle-laden gas stream to the evacuable chamber. A laser is positioned to produce a focused laser beam which intersects the particle-laden gas stream at a position approximately 0.1 mm from the chamber entrance. The laser beam has a power density sufficient to fragment and ionize particles entrained within the particle-laden gas stream. A detector is positioned to detect the ionized species produced by the laser.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a non-provisional patent application based upon provisional patent application having Ser. No. 60/127,980, filed on Mar. 19, 1999, which is owned by the same inventor.
BACKGROUND OF THE INVENTION
There are a variety of racks, holders, or the like, for use for holding a paper towel roll in place. Many of such holders include a base plate, that secures directly to the wall, and has pivotally hinged end plates, that are spring biased inwardly, so that when they are pulled under a biasing force outwardly, into a perpendicular like direction with the base plate, the paper towel may be slid therein, and once the end plates are released, they bias against and include centering posts for partially inserting within the center roll of the paper towel, to secure the same in place. There are other type holders that are also available in the art, but which require a fair amount of manipulation by the user, and some dexterity through the application of both hands, to secure the paper roll or paper towel roll, in place.
The current invention relates to an improvement in the temporary adherence of a paper towel roll to a rack, and whether the rack be secured to the wall, or simply rested upon a countertop, during its usage and application.
SUMMARY OF THE INVENTION
This invention relates generally to a paper towel holder, and more specifically pertains to a paper towel rack, which incorporates a unique centering roll, which is spring biased, and which includes a hand manipulable lever for facilitating the application and release or removal of the paper towel roll from its supporting holder.
This invention is designed for facilitating the application and holding of a paper towel roll to its holder, and which holder incorporates a base plate, the type that may be fabricated of wood, metal, polymer, or the like, having sufficient support so that it may be rested directly upon the countertop, or it may be secured by means of fastening means, such as screws, directly to the adjacent wall, for support. Likewise, pressure sensitive adhesive means may also be used for attaining such securement. At the ends of the base plate are a pair of perpendicularly extending ends plates, and which are designed having counterbores provided therein, said counterbores from each of the oppositely disposed end plates being arranged in alignment. A manipulable style of spring bias rod means, forms the holder for the towel roll, and this rod means incorporates a lever, at its one end, to facilitate its manipulation, and contraction, so as to allow for ease of insertion of the towel holder in place, and to hold a roll of towels upon this holder, once installed. More specifically, the towel holder includes a base plate, from which a pair of end plates are perpendicularly permanently mounted, and each of the end plates have a counterbore proximate their outer periphery, and into which the roll for the towel holder inserts. The roll for the towel holder includes a series of polymer formed components, but which may obviously be formed from other materials, and has a spanning portion that forms the middle segment of the roll, an outer segment at one end which is permanently affixed thereto, and which includes a lever means that extends radially outwardly, while the opposite end of the roll includes a sleeve, closed at its end, and provides a spring therein, such that when the middle segment of the roller is inserted therein, it becomes spring biased, so that it may be contracted, against the force of the spring, once a roll of towels has been applied thereon, and inserted into the counterbore of one of the end plates, biased inwardly, so as to clear the second end plate, and allow that end of the roll to be arranged within the counterbore of the said end plate, for installation of a roll of towels. All of this manipulation can be done through a grasping and shifting laterally of the roller lever, as can be understood.
It is, therefore, the principal of object of this invention to facilitate the installation and application of a roll of paper or other towels to its holder.
Still another object of this invention is to provide a spring biased roller, for use for holding a roll of towels in place, within its holder.
Still another object of this invention is the provision of lever means, to facilitate the forced contraction against the bias of a spring, when the towel roller is being installed, and allowing for its release when the roller is installed fully within its holder for suspending the roll of towels for ready usage and application.
Yet another object of this invention is to provide a lever at the end of a roller and which may be manipulated inwardly, to contract the length of the roller, when it is desired to remove either the spent of towels from its holder, or for installing a new and full supply roll of towels thereto.
These and other objects may become more apparent to those skilled in the art upon reviewing the summary of this invention, and upon undertaking a study of the description of its preferred embodiment, in view of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In referring to the drawings,
FIG. 1 provides a perspective view of the holder portion of this invention, with a roll of towels and its compressible roller removed therefrom;
FIG. 2 provides a perspective view of the towel holder, with its roller installed in place intermediate the two end plates of its holder;
FIG. 3 is a perspective view of the towel holder, with its compressible roller located in place, and having its end supporting disc applied thereon;
FIG. 4 is a perspective view of the towel holder of this invention, fully assembled and holding a roll of fresh towels thereon;
FIG. 5 is a front view of the towel holder of this invention;
FIG. 6 is a sectional view of the towel holder, showing the interior surface of its left end plate, taken along the line 6 — 6 of FIG. 5;
FIG. 7 is a top view of the towel holder of this invention;
FIG. 8 is a right side view of the towel holder of FIG. 7;
FIG. 9 is a fragmented view of the intermediate section of the towel roller;
FIG. 10 is a left end view of the roller as shown in FIG. 9;
FIG. 11 is a front view of the right side section of the towel roller;
FIG. 12 is a right end view of the section of FIG. 11;
FIG. 13 is a front view of the left section of the towel roller;
FIG. 14 is a left end view of the section of FIG. 13; and
FIG. 15 is an enlarged view of the corner of the section of the towel roller as shown in FIG. 13 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
In referring to the drawings, and in particular FIG. 1, the towel holder of this invention is disclosed, and comprises a base plate 1 , having a pair of end plates 2 and 3 , both of which are perpendicularly mounted with respect to the base plate, as can be noted. The base plate, as shown herein, may be fabricated of wood, to enhance the decorative appearance of the holder, or it may be formed of any type of a polymer, metal, or the like, depending upon the attributes of the designer.
FIG. 2 discloses the same towel holder 1 , but shows the installation of the towel roll, as at 4 , previously installed upon its holder, and in place. As noted, the roller includes a multisectioned component, having an intermediate portion 5 , a sleeve 6 , at its right segment, and which sleeve includes a lever 7 permanently affixed to its end, and which extends radially outwardly, having a bent portion, as at 8, as noted. The left segment 9 of the roller includes an inner cavity, in which a spring (not shown) is located therein, being a compression spring, and against which the middle section 5 biases, in order to contract the length of the holder 4 , when it is being installed, or to release it, and permanently hold it mounted between the end plates 2 and 3 , as can be seen.
Also, proximate the left end of the roller 4 , there may be installed a circular disc 10 , that is loosely mounted upon the left segment 9 of the roller, and which stabilizes the end of the paper towel, when located upon the paper towel holder of this invention. FIG. 4 discloses the various components for the paper towel holder as previously described in FIGS. 1 through 3, but in this instance, as can be seen, a roll of paper towels, as at P, has been applied, and located in place, for ready usage. As can be noted, the towel holder of this invention may be rested upon its base plate 1 , directly upon a countertop, or the base plate 1 may be secured by fasteners to the wall, or held by a double pressure sensitive adhesive means in place, to the wall, or the countertop, when installed.
As can be seen in FIGS. 5 through 8, the various components that fabricate the holder of this invention are shown. The base plate 1 has sufficient length spanning from side to side, and incorporates the end plates 2 and 3 in place, proximate the ends of the base plate, and spaced apart a distance slightly greater than the length of the standard roll of paper towels, so as to provide and facilitate their insertion upon the roller 4 , when held in place. As can be seen, each of the end plates 2 and 3 has a counterbore, as at 11 and 12 provided therein, and it is into these counterbores that the paper roller inserts, when installed, for holding a roll of paper towels in place. Obviously, as can also be seen in FIG. 6, the end plates, such as 2, have sufficient width, when extending outwardly from their base plate 1 , at least greater than one-half the width of a full roll of paper towels, so that clearance is provided adequately between the back surface of the roll of towels, and the front surface of the base plate 1 , when a new roll of towels is installed for usage.
FIGS. 7 and 8 show similar dimensional relationships between the base plate 1 , the end plates 2 and 3 , and the length of the end plate 3 , as can be seen.
The paper towel roller, as previously reviewed at 4, is fabricated of a series of sections. As can be seen in FIGS. 9 and 10, the middle section 5 is generally fabricated integrally of a cross-like configuration, in cross-section, as noted in FIG. 10 . Its left end is slightly reduced in size, as at 13, so that it can fit within the left segment of the roller, when assembled. The opposite end of the middle section 5 of the roller is slightly enlarged, as at 14, so that it may be pressure fitted within the right segment 6 , of the roller, as can be noted in FIG. 2 .
The right segment of the roller is shown in FIGS. 11 and 12. As can be seen, the right segment includes a cylindrical portion 15 , which is slightly enlarged at its free end 16 , so that the proximate end of the middle segment 5 of the roller, as at 14, can be pressure fitted therein. In addition, the opposite end of the right segment 6 has a series of tiered reduced portions, as at 17, so as to accommodate their locating and pivotally mounting within the counterbore 12 of the proximate end plate 3 , when the roller is installed. In addition, there is an integral lever provided at 18, and which has an integral bent configuration at 19, to where it extends for connecting onto the right segment 6 , as can be noted, and also to provide adequate clearance for the finger, when one grasps the lever at this location, as when the paper roll is being installed, or removed, as may be desired.
The left segment 9 of the roller is shown in FIGS. 13 through 15, and it is fabricated having a central cavity therein, so that the reduced end 13 of the middle section 5 of the roller can insert therein, and be slid longitudinally with respect thereto, for biasing against a compression spring (not shown), that also locates within the interior of this left section 9 of the roller. It can also be seen that the left section 9 , at its end, includes a tiered integral segment 20 , that is designed for easily being aligned with and inserting within the counterbore 11 of the end plate 2 , at the opposite end of the holder, when the roller is installed in place.
As can be generally understood, when it is desired to add a fresh roll of paper towels to the paper towel holder of this invention, one simply grasps the lever 18 , proximate its outer portion, pushes the right segment 6 of the roller to the left, thereby forcing its middle section 5 to urge against the compression spring (not shown), located within the left segment 9 , so as to contract or reduce the longitudinal length of the roller, and provide clearance for removal of their tiered ends 17 and 20 , respectively, from within the counterbores 12 and 11 , of the end plates 2 and 3 . Once removed, a fresh roll of paper towels may be located upon the composite roller, the tiered end 20 may be inserted within its respective counterbore 11 , of the left end plate 2 , the lever 18 will be compressed inwardly, so as to contract the length of the roller 5 , providing clearance for the opposite tiered end 17 to pass within the end plate 3 , and arrange its tiered end 17 into the counterbore 12 , such that when the lever 18 is released, it becomes pivotally mounted therein. Thus, a fresh roll of paper towels will be installed for usage, and can be freely pulled therefrom, since there will be little or no resistance against the turning of paper roll upon its roller 5 , when used. Then, after the paper towels have been exhausted, the roller 5 can be removed in a similar manner, by reversing the steps described above, so as to remove the roller from its holder, discard the spent paper towel roll core, and adding a new roll of paper towels thereon, for immediate installation.
Variations or modifications to the subject matter of this invention may occur to those skilled in the art upon reviewing the disclosure as provided herein. Such variations or modifications, if within the spirit of this disclosure, are intended to be encompassed within the scope of the invention as defined.
The description of the preferred embodiment as provided herein, and as depicted in the drawings, is set forth for illustrative purposes only.
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A paper towel holder incorporating structure to facilitate the application and release of a roll of paper towels, including a holder, having a base plate, a pair of perpendicularly mounted end plates secured thereto, a compressible towel roller installs intermediate the end plates, and within their respective counterbores, for holding a roll of paper towels in place during usage. The roller is formed of three segments, a center, left, and right segment, which are compressible with respect to each other, due to the presence of a compression spring within the left segment, against which the middle segment biases when the roller is being contracted in size to allow for its installation intermediate the end plates of the holder.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/366,737 filed Jul. 22, 2010 and entitled Low Noise and Vibration Flexible Shaft Assembly.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a rotatable flexible shaft transmitting torque with reduced noise and vibration.
[0003] Such shafts normally have ends of square cross-section which are adapted to engage square recesses in mating torque transmitting and receiving members. When such a shaft is rotated, noise is generated due to movement of the shaft ends within the mating recesses. It is not possible to provide an exact fit between the shaft ends and the recesses, since manufacturing tolerances must be maintained to insure the ends can be inserted into the recesses when the associated devices, such as motor vehicle seats, are assembled.
[0004] Prior art efforts to reduce such noise and vibration include applying flocked yarn or flock fibers, grease, or heat shrink tubing such as polytetrafluoroethylene to the lateral surfaces of the shaft ends. See, for example, U.S. Pat. No. 7,717,795 to Mellor.
[0005] Such prior art constructions have various disadvantages such as significant manufacturing expense, fabrication difficulty, limited durability, limited useful life, and/or a performance level less than that desired.
[0006] Patent Application Publication No. US 2008/0220883 of Yuen shows a noise and vibration reducing construction wherein felt or a material having similar mechanical characteristics is wrapped around a major part of the shaft to reduce noise and vibration due to contact with the surrounding casing. U.S. Pat. No. 5,558,578 to Uryu et al. discloses compressed felt coaxial sheaths which surround spaced portions of the shaft. However, further reduction of noise and vibration is generally desired.
[0007] Patent Application Publication No. US 2010/0252359 of Yuen shows a noise reducing construction wherein the shaft ends have raised portions of compressible material such as flocked yarn covered with plastic tubing. This construction also fails to provide the desired level of durability, useful life, and noise and vibration reduction.
[0008] Accordingly, an object of the present invention is to provide an improved reduced noise and vibration flexible shaft which can readily be manufactured at reasonable cost and which exhibits improved durability and useful life.
SUMMARY OF THE INVENTION
[0009] According to the invention, a torque transmitting wire wound flexible shaft has noncircular end portions, preferably having a square or helical square shape and chamfered end portions. Felt strips are wrapped around and adhered to all or part of the end portions including the distal end surfaces thereof, and may be wrapped around all or part of the chamfered parts of those end portions. Overlapping parts of the felt strips are preferably fused together, in which case they are made of thermoplastic material.
IN THE DRAWING
[0010] FIG. 1 is an isometric view of a flexible shaft according to a first embodiment of the invention.
[0011] FIG. 2 a is an isometric view of one tip of the shaft shown in FIG. 1 .
[0012] FIG. 2 b is a front elevation view of the shaft tip shown in FIG. 2 a.
[0013] FIG. 2 c is a front cross-sectional view of the shaft tip shown in FIG. 2 b , taken along the cutting plane A—A.
[0014] FIG. 3 a is an isometric view of a flexible shaft tip according to a second embodiment of the invention.
[0015] FIG. 3 b is a front elevation view of the shaft tip shown in FIG. 3 a.
[0016] FIG. 3 c is a front cross-sectional view of the shaft tip shown in FIG. 3 b , taken along the cutting plane A—A.
[0017] FIG. 4 a is an isometric view of a flexible shaft tip according to a third embodiment of the invention.
[0018] FIG. 4 b is a front elevation view of the shaft tip shown in FIG. 4 a.
[0019] FIG. 4 c is a front cross-sectional view of the shaft tip shown in FIG. 4 b , taken along the cutting plane A—A.
[0020] FIG. 5 a is an isometric view of a flexible shaft tip according to a fourth embodiment of the invention.
[0021] FIG. 5 b is a front elevation view of the shaft tip shown in FIG. 5 a.
[0022] FIG. 5 c is a front cross-sectional view of the shaft tip shown in FIG. 5 b , taken along the cutting plane A—A.
[0023] FIG. 6 a is an isometric view of a flexible shaft tip according to a fifth and preferred embodiment of the invention.
[0024] FIG. 6 b is a front elevation view of the shaft tip shown in FIG. 6 a.
[0025] FIG. 6 c is a front cross-sectional view of the shaft tip shown in FIG. 6 b , taken along the cutting plane A—A.
[0026] FIG. 6 d is a left side cross-sectional view of the shaft tip shown in FIG. 6 b , taken along the cutting plane B—B.
DETAILED DESCRIPTION
[0027] The wire wound flexible shaft 10 shown in FIGS. 1 to 2 c has a central generally cylindrical major portion 1 a with noncircular end portions 11 a and 11 b which have tips 1 b and 1 c respectively of square cross-section and chamfered transition parts 12 a and 12 b between the tips and the major portion of the shaft.
[0028] The shaft tips may if desired have a helical square end shape such as that shown in U.S. Pat. No. 6,464,588 to Rupp. Both the square and helical square tip shapes have a square cross-section.
[0029] Alternatively, the tips may have other geometries such as generally conical, dome-shaped, or of complex shape, so long as they have a noncircular cross-section.
[0030] As best seen in FIGS. 2 a and 2 c , a single felt strip 2 a covers part of the front and rear surfaces 13 a and 13 b of tip 1 b as well as the tip end surface 13 c.
[0031] The felt strip 2 a preferably comprises a thermoplastic felt and is glues to the adjacent parts of the tip 1 b . Alternatively, wool, a rayon-wool composite, or another felt material may be used.
[0032] The felt strip 2 a should have a thickness and compressibility consistent with the manufacturing tolerance between the shaft tip and the mating recess of a driving or driven member into which the tip is to be inserted. When so inserted, the felt is compressed to accommodate, that is, partially fill the space between the tip and mating recess, resulting in reduced noise and vibration when the shaft is rotated.
[0033] While only one shaft tip is shown and described in detail, the opposite shaft tip of each embodiment is covered with felt to a similar extent and in a similar manner.
[0034] In the first embodiment the upper and lower surfaces of the shaft tips are not covered; while in the other embodiments all four tip lateral surfaces are covered with felt. In the fourth embodiment ( FIGS. 5 a - 5 c ) the ends of the shaft tips are only partially covered with felt, while in the other embodiments the ends are substantially fully covered.
[0035] In the second embodiment ( FIGS. 3 a - 3 c ) two felt strips 3 a and 3 a ′ cover the tip 1 b . Strip 3 a covers part of the front and rear surfaces 13 a and 13 b of tip 1 b as well as the tip end surface 13 c ; while strip 3 a ′ covers part of the upper and lower surfaces 13 d and 13 e of tip 1 b as well as the tip end surface 13 c , where strip 3 a ′ overlaps strip 3 a.
[0036] Felt strips 3 a and 3 a ′ comprise a thermoplastic material and are glued to the adjacent surfaces of the tip 1 b . After they are applied, a hot anvil is used to contact the overlapping parts of the strips at the tip end 13 c , to cause those parts to fuse together.
[0037] Instead of using two strips to cover the tip end in the second embodiment, a single piece of felt having the shape of a cross can be used, with the center of the cross shape being applied to the tip end 13 c and the arms covering the adjacent lateral surfaces 13 a , 13 b , 13 d and 13 e of the tip 1 b.
[0038] In the third embodiment ( FIGS. 4 a - 4 c ) thermoplastic felt tape 4 a is helically wrapped around and glued to the end of the tip 1 b in such a manner that adjacent turns are close to each other but do not overlap. The tape is overwound at the tip end 13 c so that a small part of the tape extends beyond the tip end. The extending part of the tape is then contacted with a hot anvil to cause the extending part to fuse so as to form a fused felt bulge 4 b on the tip end 13 c.
[0039] The fourth embodiment ( FIGS. 5 a - 5 c ) is the same as the fourth embodiment, except that the tape 4 a is overwound by a smaller amount so that after fusing of its extending part, the resulting bulge covers only a peripheral portion of the tip end, leaving a central part of the end exposed.
[0040] In the fifth and preferred embodiment ( FIGS. 6 a - 6 d ) a single piece of thermoplastic felt 6 a is wrapped around the end 13 c of the tip 1 b and overwound at the tip end 13 c so that a small part of the tape extends beyond the tip end. The extending part of the tape is then contacted with a hot anvil to cause the extending part to fuse so as to form a fused felt bulge 6 b on the tip end 13 c.
[0041] The shaft end portion 4 a is covered by continuous felt strips 5 a and 6 a , while the end portion 4 b is covered by continuous felt strips 5 b and 6 b . Each strip is glued to the adjacent portion of the corresponding shaft end.
[0042] Strip 5 a covers the upper and lower surfaces of end portion 4 a and wraps around the distal end 7 a thereof; while strip 6 a covers the front and rear surfaces of end portion 4 a and also wraps around distal end 7 a . As a result, the strips 5 a and 6 a overlap on the distal end 7 a.
[0043] Similarly, strip 5 b covers the upper and lower surfaces of end portion 4 b and wraps around the distal end 7 b thereof; while strip 6 b covers the front and rear surfaces of end portion 4 b and also wraps around distal end 7 b . As a result, the strips 5 b and 6 b overlap on the distal end 7 b.
[0044] The distal ends 7 a and 7 b are chamfered to facilitate insertion into mating recesses of driving and driven members of an associated device (not shown).
[0045] The felt strips or tape are secured to the adjacent surfaces of the shaft end portions by glue suitable for adhering the particular felt being used to the tip metal without saturating the felt.
[0046] If desired, the felt strips or tape may extend so far along the tips that part or all of the chamfered portions 12 a are covered. Instead of felt, a similar compressible, vibration damping material may be used. The felt or similar material prevents rattle by filling the space between the shaft end portion and mating hole with compressible, vibration damping material which deforms upon engagement of the shaft end portion and hole to conform itself to that space.
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A flexible shaft having square or helical square tips with thermoplastic felt covering and adherent to the tips including the tip ends. The felt has fused bulges adjacent the ends. When the tips are inserted into mating recesses of driving and driven members, the felt is deformed to improve the fit between the tips and the recesses and reduce noise and vibration when the driving member is rotated.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application and claims priority under 35 USC §120 to U.S. patent application Ser. No. 12/414,086, filed on Mar. 30, 2009 (U.S. Pat. No. 7,937,654 to be issued on May 3, 2011), which is a continuation application of and claims priority to U.S. patent application Ser. No. 11/112,015 filed on Apr. 22, 2005, now U.S. Pat. No. 7,511,720, which is a divisional application of and claims priority to U.S. application Ser. No. 09/635,999, filed on Aug. 9, 2000, now U.S. Pat. No. 6,915,484, the contents of which are hereby incorporated.
BACKGROUND OF THE INVENTION
The present invention relates generally to a system and method for generating output for computer systems, and more particularly to a system and method for modifying the presentation of structured documents.
The rapid expansion of the World Wide Web—where dynamic, compelling images are crucial—has driven the demand for a document format that preserves all of the fonts, formatting, colors, and graphics of any source document, regardless of the application and platform used to create it.
One such format is referred to as the portable document format (PDF). PDF is a file format developed by Adobe Systems, Incorporated. PDF captures formatting information from a variety of desktop publishing applications, making it possible to send formatted documents and have them appear on the recipient's monitor or printer as they were intended.
A source document can be authored in a page description language (PDL). PDL is a language for describing the layout and contents of a printed page. One well-known PDL is PostScript™ by Adobe Systems, Inc. PostScript describes a page in terms of page objects including textual objects and graphical objects such as lines, arcs, and circles. Moreover, PDF is a PDL.
According to conventional methods, a PDL document is rendered by first defining a bounding box, such as a page, and then placing the textual and graphical objects defined for the page into the bounding box according to the definitions in the PDL document. Normally the size of a PDL page is chosen so that it is clearly legible on a standard full-sized display. For example, an 8-inch page width may be chosen for display on a 15-inch computer monitor.
However, a single page size may not be ideal for devices having non-standard display sizes, such as a hand-held personal digital assistant (PDA). To view a PDL page having an 8-inch page width on a 3-inch-wide display, the user has two alternatives. The user can change the zoom factor of the display to show the entire page on the 3-inch display. However, this approach will generally render the page too small to be legible. Alternatively, the user can simply show a portion of the page at full magnification, and scroll horizontally and vertically to view the rest of the page. This approach is inconvenient and time-consuming.
Another approach is for the author of the PDL page to generate a different PDL page for each display size using the application that created the PDL page. This approach is wasteful because multiple copies of each PDL page must be maintained. In addition, the user must select the copy that is appropriate for the display on which the PDL page will be viewed.
SUMMARY OF THE INVENTION
In general, in one aspect, the invention features a method and computer program product for reflowing a PDL page without using the original application used to create the PDL page. One use of the present invention is to resize a page for viewing on a display of a different size than the display to which the document was originally rendered, or to display at a different resolution, either because the inherent resolution of the display differs, or because the reader has demanded a larger, more visible representation.
In one aspect the method and computer program product include receiving a page represented in a page description language, the page including a plurality of page objects; and changing a size of the page to a changed size in a first dimension without changing the size of the page objects, while maintaining spatial relationships between the page objects in a second dimension.
Particular implementations can include one or more of the following features. The page objects can include textual and graphical elements, and the changing step includes maintaining spatial relationships between the textual and graphical elements in the second dimension. The changing step can further include creating one or more new pages having the changed size in the first dimension; and adding the textual and graphical elements to the one or more new pages. The adding step can include identifying distances in the second dimension between one or more textual elements and one or more graphical elements; adding the textual elements to the one or more new pages; and adding the graphical elements to the one or more new pages based on the distances in the second dimension and positions of the textual elements in the one or more new pages. The identifying step can include creating a map containing the positions of the textual elements in the page, and augmenting the map with the positions of the textual elements in the one or more new pages to produce a relationship for each textual element between the position of the textual element in the page and the position of the textual element in the one or more new pages; and the step of adding the graphical elements can include adding the graphical elements to the one or more new pages according to the map. The step of adding the graphical elements according to the map can include associating one or more particular textual elements with one or more particular graphical elements; determining distances in the second dimension between the particular textual elements and the particular graphical elements; and selecting positions in the one or more new pages for placement of the particular graphical elements based on the distances and the positions of the particular textual elements in the one or more new pages as listed in the map. The associating step can include associating a particular graphical element with a particular textual element that is nearest to the particular graphical element in the first dimension. The associating step can include associating a given graphical element with a plurality of given textual elements; and the selecting step can include scaling the given graphical element when a distance in the first dimension between the plurality of given textual elements in the page differs from a corresponding distance between the plurality of given textual elements in the one or more new pages. The textual elements can be organized as words.
In another aspect the method and computer program product include receiving a page represented in a page description language, the page including a plurality of page objects; and changing a size of the page objects without changing the size of the page, while maintaining spatial relationships between the page objects in a dimension of the page. The page objects can include textual and graphical elements, and the changing step can include maintaining spatial relationships between the textual and graphical elements in the dimension. The changing step can include creating one or more new pages having the same size as the page in a further dimension; scaling the textual and graphical elements, producing scaled textual and graphical elements; and adding the scaled textual and graphical elements to the one or more new pages. The adding step can include identifying distances in the dimension between one or more textual elements and one or more graphical elements; adding the scaled textual elements to the one or more new pages; and adding the scaled graphical elements to the one or more new pages based on the distances in the dimension and the positions of the scaled textual elements in the one or more new pages. The identifying step can include creating a map containing the positions of the textual elements in the page, and augmenting the map with the positions of the textual elements in the one or more new pages to produce a relationship for each textual element between the position of the textual element in the page and the position of the corresponding scaled textual element in the one or more new pages; and the step of adding the graphical elements can include adding the graphical elements to the one or more new pages according to the map. The step of adding the scaled graphical elements according to the map can include associating one or more particular textual elements with one or more particular graphical elements; determining distances in the dimension between the particular textual elements and the particular graphical elements; and selecting positions in the one or more new pages for placement of the scaled graphical elements corresponding to the particular graphical elements based on the distances and the positions of scaled textual elements corresponding to the particular textual elements in the one or more new pages as listed in the map. The associating step can include associating a particular graphical element with a particular textual element that is nearest to the particular graphical element in the further dimension. The associating step can include associating a given graphical element with a plurality of given textual elements; and the selecting step can include scaling the given graphical element in the dimension when a distance in the dimension between the plurality of given textual elements in the page differs from a corresponding distance in the one or more new pages between a plurality of scaled textual elements corresponding to the plurality of given textual elements. The textual elements can be organized as words.
In another aspect the method and computer program product include receiving a page represented in a page description language, the page including a plurality of page objects; and changing a size of the page to a changed size in a first dimension, and changing a size of one or more of the page objects, while maintaining spatial relationships between the page objects in a second dimension. The page objects include textual and graphical elements, and wherein the changing step can include maintaining spatial relationships between the textual and graphical elements in the second dimension. The changing step can include creating one or more new pages having the same size as the page in a further dimension; scaling the textual and graphical elements, producing scaled textual and graphical elements; and adding the scaled textual and graphical elements to the one or more new pages. The adding step can include identifying distances in the second dimension between one or more textual elements and one or more graphical elements; adding the scaled textual elements to the one or more new pages; and adding the scaled graphical elements to the one or more new pages based on the distances in the second dimension and positions of the textual elements in the one or more new pages. The identifying step can include creating a map containing the positions of the textual elements in the page, and augmenting the map with the positions of the textual elements in the one or more new pages to produce a relationship for each textual element between the position of the textual element in the page and the position of the corresponding scaled textual element in the one or more new pages; and the step of adding the graphical elements can include adding the graphical elements to the one or more new pages according to the map. The step of adding the graphical elements according to the map can include associating one or more particular textual elements with one or more particular graphical elements; determining distances in the second dimension between the particular textual elements and the particular graphical elements; and selecting positions in the one or more new pages for placement of the scaled graphical elements corresponding to the particular graphical elements based on the distances and the positions of scaled textual elements corresponding to the particular textual elements in the one or more new pages as listed in the map. The associating step can include associating a particular graphical element with a particular textual element that is nearest to the particular graphical element in the first dimension. The associating step can include associating a given graphical element with a plurality of given textual elements; and the selecting step can include scaling the given graphical element when a distance in the dimension between the plurality of given textual elements in the page differs from a corresponding distance in the one or more new pages between a plurality of scaled textual elements corresponding to the plurality of given textual elements. The textual elements can be organized as words. The amount of size change of a page object can depend on the type of the page object.
In general, in one aspect, the invention features a method and computer program product for forming illustrations in a page. It includes receiving a page represented in a page description language (PDL), the page including a plurality of page objects including line art elements, each page object associated with a PDL element range including at least one PDL element; repeatedly augmenting each PDL range with a PDL element that is adjacent to the PDL range and is not part of another PDL range when the bounding box of the PDL element overlaps the bounding box of the PDL object associated with the PDL range; such that the PDL elements in each PDL range define an illustration. Particular implementations can include combining two illustrations when their PDL ranges are adjacent and their bounding boxes overlap.
In another aspect the method and computer program product include receiving a page represented in a page description language (PDL), the page including a plurality of page objects including line art elements, each page object associated with a PDL element range including at least one PDL element; recursively coalescing line art elements having overlapping bounding boxes to form one or more illustrations; adding to each illustration each PDL element within the PDL range of the illustration that is not part of the illustration when the bounding box of the PDL element overlaps the bounding box of the illustration; and repeatedly augmenting the PDL range of each illustration with PDL elements that are adjacent to the PDL range and are not part of another illustration when the bounding box of the PDL elements overlap the bounding box of the illustration; such that the PDL elements in each PDL range define an illustration. Particular implementations can include combining two illustrations when their PDL ranges are adjacent and their bounding boxes overlap. The step of recursively coalescing can include combining two line art elements having overlapping bounding boxes, thereby forming an illustration; and creating a new bounding box containing the illustration. Particular implementations can include combining a line art element with the illustration when the bounding boxes of the line art element and the illustration overlap.
Advantages that can be seen in implementations of the invention include one or more of the following. PDL pages can be resized. A PDL page produced according to the invention can be legibly displayed on any size display.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features and advantages of the invention will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a computing system for displaying a document.
FIG. 2 depicts a conventional PDL page.
FIG. 3 depicts a PDL page resulting from the operation of one implementation of the present invention.
FIG. 4 depicts a PDL page resulting from the operation of another implementation of the present invention.
FIG. 5 depicts a PDL page resulting from the operation of yet another implementation of the present invention.
FIG. 6 is a flowchart depicting a process for reflowing a PDL page.
FIGS. 7-10 show the results of the process of FIG. 6 when applied to a PDL page containing eleven PDL elements.
FIG. 11 depicts a process for forming illustrations.
FIG. 12 is a flowchart depicting an alternative process for forming illustrations.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
The present invention can be implemented in a raster image processor (RIP). This implementation is described with reference to FIG. 1 .
FIG. 1 is a block diagram of a computing system 100 for displaying a document. In system 100 , an application 102 , such as a word processor, generates a request to display a page in response to a user selection. The request is sent to an operating system 104 , such as Windows™, using an operating system call. The operating system 104 in turn directs the request to a page description language (PDL) driver 106 . The driver 106 translates the operating system calls and generates a data stream that is sent to RIP 120 . RIP 120 operates to generate an encoded raster file 122 . The encoded raster file is sent to display device 130 for display.
The implementation described below changes only the page width, and not the size of the page objects. In another implementation, only the size of the page objects is changed. In yet another implementation, both the page width and the size of the page objects are changed. In variations of these implementations, it is the page length that is changed, rather than the page width. These variations are especially useful for languages that are written from top to bottom, rather than from left to right. The textual elements can be organized as characters, words and the like.
FIG. 2 shows a conventional PDL page 202 . The page includes textual elements 206 and graphical elements 208 and 210 . The page has a page width 220 . Each graphical element in a page is associated with one or more textual elements in the page. Graphical element 208 spans several lines of text. Therefore, it is associated with two textual elements 212 (“I”) and 214 (“desperate”). For convenience, textual elements 212 and 214 , referred to as “anchors,” are shown in bold type. Graphical element 210 spans only a single line. Therefore, it is associated with a single anchor 216 (“My”).
FIG. 3 shows a PDL page 302 after application of the reflow process of the present invention. The width of the original PDL page 202 is changed while the font size of a textual element 206 remains constant. Referring to FIGS. 2 and 3 , the page width 320 of new page 302 is chosen to be narrower than the page width 220 of original page 202 . Accordingly, the length of the page increases. When referring to a PDL page, the horizontal dimension is referred to as its X-axis and the vertical dimension is referred to as the Y-axis. Thus, it is the distance in the Y-axis that increases. In this implementation, the graphical elements are moved and stretched to follow their anchors.
The Y-axis position of anchor 216 has also increased. Therefore, the Y-axis position of associated graphical element 210 is also increased so that anchor 216 and graphical element 210 are aligned on the Y-axis. In addition, the Y-axis distance between anchors 212 and 214 has increased. Therefore, corresponding graphical element 208 is stretched to span the distance between anchors 212 and 214 .
FIG. 4 shows a PDL page 402 resulting from the operation of another implementation of the present invention. In this implementation, the width of the PDL page remains constant while the font size of its textual elements is increased. Referring to FIGS. 2 and 4 , the page width 420 of page 402 is the same as the page width 220 of page 202 ( FIG. 2 ). However, the font size of the textual elements 206 has been increased from 12 points to 14 points. Therefore, the length of the page 402 is greater than the length of page 202 .
The Y-axis position of anchor 216 has also increased. Therefore, the Y-axis position of associated graphical element 210 is increased so that anchor 216 and graphical element 210 are aligned on the Y-axis. In addition, the Y-axis distance between anchors 212 and 214 has increased. Therefore, corresponding graphical element 208 is stretched to span the distance between anchors 212 and 214 .
FIG. 5 shows a PDL page 502 resulting from the operation of another implementation of the present invention. According to this implementation, the width of the PDL page and the font size of its textual elements are increased. Referring to FIGS. 2 and 6 / 5 , the page width 520 of new page 502 is chosen to be narrower than the page width 220 of original page 202 . In addition, the font size of the textual elements 206 has been increased from 12 points to 14 points. Therefore, the length of the page 502 is greater than the length of page 202 .
The Y-axis position of anchor 216 has also increased. Therefore, the Y-axis position of associated graphical element 210 is increased so that anchor 216 and graphical element 210 are aligned on the Y-axis. In addition, the Y-axis distance between anchors 212 and 214 has increased. Therefore, corresponding graphical element 208 is stretched to span the distance between anchors 212 and 214 .
FIG. 6 is a flowchart depicting a process for reflowing a PDL page. According to this process, only the width of the PDL page is changed. The size of the textual elements within the PDL page remains constant. In another implementation, the size of the textual elements is increased while the page width is unchanged, as shown in FIG. 4 . In another implementation, both the page width and the font size of the textual elements are changed, as shown in FIG. 5 .
A PDL page is received in step 602 . The PDL page includes page objects and including textual and graphical elements. In step 604 , the process creates a new PDL page having a page width that differs from that of the received original PDL page. Note that all of the implementations maintain the spatial relationship between the textual and graphical elements.
In one implementation, two or more new PDL pages are created. The textual elements are added to the new PDL page in step 606 . Next sub-process 620 is repeated for each graphical element.
The graphical element is associated with one or more textual elements in step 608 . Then the process determines a Y-axis difference between the position of the graphical element and a position of each associated textual element, as shown in step 610 . This step is useful when a graphical element and its associated textual element do not have the same Y-axis position.
In one implementation, the Y-axis positions of each textual element in the original PDL page and the new PDL page are recorded in a “Y-map.” An exemplary Y-map is shown in Table 1. Table 1 is a Y-map between page 202 of FIG. 2 and page 302 of FIG. 3 . Table 1 presents the Y position in the old page (page 202 ) and the Y position in the new page (page 302 ) for the anchor textual elements. In another implementation, the Y-map records positions for each textual element. Referring to Table 1, it is seen that the textual element “I” (anchor 212 ) is at a Y-axis position of 0.25 in both the old and new pages. However, the word “desperate” (anchor 214 ) has moved by half an inch. Similarly, the word “My” (anchor 216 ) has moved by ¾ of an inch.
TABLE 1
Textual Element
Y Position in Old Page
Y Position in New Page
I
0.25
0.25
desperate
1.75
2.25
My
2.00
2.75
A position for the graphical element in the new page is then determined based on the Y-axis position of the associated textual element(s) in step 612 . For example, the position of graphical element 210 in page 302 is determined based on the Y-axis position of its associated textual elements (anchor 216 ) in page 302 . Referring to the Y-map of Table 1, it is seen that the Y-axis position of anchor 216 is 2.75 inches. Therefore, assuming that the Y-axis difference between graphical element 210 and anchor 216 is zero, the position for graphical element 210 in page 302 is determined to be 2.75 inches along the Y-axis. If necessary, the graphical element is scaled (that is, stretched) in step 614 . For example, referring to FIG. 3 , graphical element 208 is stretched because its associated anchors 212 and 214 are further apart than in the original page. Finally, the graphical element is placed at the position determined in step 612 , as shown in step 616 .
The present invention is also useful in documents having multiple columns. Each column is simply treated according to the process of FIG. 6 within its bounding box in the same way the PDL page 202 is treated within page 302 . Implementations of the present invention include three variations to handle different multi-column cases. For example, consider a two-column case with a vertical line-art element between the two columns. Each column has a Y-map, so there are two Y-maps. The vertical line-art element is associated with textual elements in both columns. When reflowing the line-art element, it must be decided which Y-map to use. In one implementation, the Y-map having the maximum Y value for the line-art element is used. Other implementations can be used, as would be apparent to one skilled in the relevant arts.
In a multiple column case, where a single text-line or line-art element intersects the X-axis extent of a set of columns, that intersection is considered to be a “fault line.” This fault line is used as a break, so that subsequent text (that is, text that has a greater Y-axis position than the fault line) is considered to be a new column.
An implementation of the present invention handles hyphenation and ligatures according to the following method. The process hyphenates a word at a line-end in the new page if the original word had a soft hyphen at that point. Similarly, such a word can be unhyphenated when it is no longer at a line-end in the new page. In implementations in which the font size of the text elements is changed, the positioning of the text lines is addressed. In one implementation, all vertical white space is retained. That is, the inter-paragraph vertical gap is retained, and within the paragraph, the inter-line vertical gap is retained.
In the implementation discussed above, the graphical elements can be simple line art elements, images, or combinations of line art elements, images and text, such as captions. PDF documents often contain complex illustrations including multiple graphical elements, such as strokes and fills, images, and even textual elements, such as captions. Humans are very good at identifying which components belong to a particular illustration. However, in order to successfully reflow a document containing a complex illustration, it is desirable to perform this process automatically. After an illustration is identified, it can be reflowed into the new page according to the process described above.
FIGS. 8-10 graphically depict combining page objects to form a single illustration. FIG. 7 represents a PDL page containing eleven PDL elements. PDL elements E 1 , E 2 , E 3 , E 4 , E 5 and E 6 are line art elements forming a “stick man” standing on the ground. PDL elements E 7 and E 9 are line art elements representing balloon tethers. PDL elements E 8 and E 10 are images representing balloons. PDL element E 11 is a text element that is the caption for the drawing.
The process begins by coalescing line art elements to form illustrations. Each line art element is assigned a “bounding box.” In the described implementation, each bounding box is rectilinear having sides parallel to the edges of the PDL page. Referring to FIG. 8 , PDL element E 7 is enclosed by bounding box 802 , and PDL element E 9 is enclosed by bounding box 804 .
According to the process, when line art elements have overlapping bounding boxes, they are combined to form a single illustration. This illustration, I 2 , contains the elements E 7 and E 9 and can be represented by
I2=E7, E9 (1)
The drawing of FIG. 7 is represented by a sequential collection of PDL elements given by equation 1. Assume that PDL elements forming the stickman standing on the ground have already been collected to form an illustration I 1 given by
I1=E1, E2, E3, E4, E5, E6 (2)
The sequence of PDL elements, from first to last, associated with an illustration is referred to as its “range.” The PDL representation of the drawing of FIG. 7 is given below with the range of illustrations I 1 and I 2 underlined.
PDL=E1, E2, E3, E4, E5, E6, E7, E8, E9, E10, E11 (3)
Note that, although element E 8 is not part of illustration I 2 , it falls within the range of illustration I 2 . The treatment of such “gaps” in range is described below.
The process recursively joins line-art elements to form illustrations. Referring to FIG. 9 , illustration I 2 has been enclosed in bounding box 902 , and illustration I 1 has been enclosed in bounding box 904 . Because bounding boxes 902 and 904 overlap, the process coalesces the contained line-art elements to form an illustration I 3 given by equation 6.
I3=E1, E2, E3, E4, E5, E6, E7, E9 (4)
The PDL range of illustration I 3 then runs from E 1 to E 9 . The PDL sequence for FIG. 9 is given below with the range of illustration I 3 underlined.
PDL= E1, E2, E3, E4, E5, E6, E7, E8, E9 , E10, E11 (5)
The process next seeks to fill gaps in the range such as that represented by element E 8 . At this point, all of the line-art elements in the PDL page have been coalesced to form illustrations. Now the process seeks to combine those illustrations with other PDL elements such as images and text. The first step of this process is to fill the gaps in the PDL ranges of the line-art illustrations. Referring to FIG. 10 , PDL element E 8 is an image that lies within the range of illustration I 3 . The process combines a PDL element with an illustration if it lies within the PDL range of that illustration and the bounding boxes of the illustration and the PDL element overlap. Referring to FIG. 10 , illustration I 3 has been enclosed in a bounding box 1002 , and image E 8 has been enclosed within a bounding box 1004 . Bounding boxes 1002 and 1004 overlap. Therefore, element E 8 is combined with illustration I 3 . Illustration 13 now combines all of the elements from E 1 to E 9 as shown below.
I3=E1, E2, E3, E4, E5, E6, E7, E8, E9 (6)
The PDL representation of FIG. 10 is given below, with the range of I 3 underlined.
PDL= E1, E2, E3, E4, E5, E6, E7, E8, E9 , E10, E11 (7)
The process then seeks to combine PDL elements that are adjacent to the range of an illustration. A PDL element will be combined with an illustration when it is adjacent to the illustration in the PDL sequence and the bounding boxes of the illustration and the PDL element overlap. Referring to equation 9, we see that image El 0 is adjacent to the range of illustration I 3 . Referring to FIG. 10 , we see the bounding box 1006 of image E 10 and the bounding box 1002 of illustration I 3 overlap. Therefore, image E 10 is combined with illustration I 3 . As a result, illustration I 3 is given by
I3=E1, E2, E3, E4, E5, E6, E7, E8, E9, E10 (8)
The PDL representation of the drawing is then given by
PDL= E1, E2, E3, E4, E5, E6, E7, E8, E9, E10 , E11 (9)
Referring to equation 11, it is seen that text element E 11 is adjacent to the range of illustration I 3 . Referring to FIG. 10 , it is seen that the bounding box 1008 of element E 11 and bounding box 1002 illustration I 3 overlap. Therefore, text element E 11 is combined with illustration I 3 . Illustration I 3 has been given by
I3=E1, E2, E3, E4, E5, E6, E7, E8, E9, E10, E11 (10)
The PDL range of the drawing has been given by
PDL= E1, E2, E3, E4, E5, E6, E7, E8, E9, E10, E11 (11)
It is seen that all of the elements within the drawing have now been combined to form a single illustration.
FIG. 11 depicts a process for forming illustrations according to an implementation of the present invention. A PDL page is received at step 1102 . The PDL page includes page objects including line-art elements. The page objects can also include other sorts of PDL elements such as images and text elements. Each page object is associated with a PDL element range that includes at least one PDL element. It is possible that an illustration generated in this way is simply part of a background. Therefore, if a page element illustration is the same color as the background, it is discarded in step 1103 .
The line-art elements within the PDL page are recursively coalesced to form illustrations at step 1104 . The first recursion includes combining two line-art elements when their bounding boxes overlap to form an illustration. Following recursions include combining the illustration and a line-art element when their bounding boxes overlap to form the next illustration.
As described above, the range of an illustration may include PDL elements that are not part of the illustration. These PDL elements represent “gaps” in the PDL range. These “gaps” are located at step 1105 . Each such “gap” is tested to determine whether it should be joined with the illustration at step 1106 . A PDL element within the range of an illustration is combined with that illustration when the bounding boxes of the element and the illustration overlap.
The process then tests PDL elements that are adjacent to the ranges of the illustrations to determine whether they should be joined with those illustrations in step 1108 . In one implementation, only those elements that are not already a part of another illustration are tested. A PDL element that is adjacent to the range of an illustration is combined with that illustration when the bounding boxes of the element and illustration overlap. This step is also performed recursively to “grow” the illustrations as the range of each illustration increases.
The process then tests the illustrations to determine whether any of them should be joined to form a single illustration in step 1110 . Illustrations are combined when their PDL ranges are adjacent and their bounding boxes overlap.
Each PDL range that results from this process is a separate illustration. Each illustration is treated as a separate graphical element in the reflow process described above.
FIG. 12 is a flowchart depicting a process for forming illustrations according to another implementation of the present invention. A PDL page is received at step 1202 . The PDL page includes page objects including line-art elements. The page objects can also include other sorts of PDL elements such as images and text elements. Each page object is associated with a PDL element range that includes at least one PDL element.
The process then tests PDL elements that are adjacent to the ranges of the illustrations to determine whether they should be joined with those illustrations in step 1204 . In one implementation, only those elements that are not already a part of another illustration are tested. A PDL element that is adjacent to the range of an illustration is combined with that illustration when the bounding boxes of the element and illustration overlap. This step is also performed recursively to “grow” the illustrations as the range of each illustration increases.
According to one implementation, each illustration is classified for treatment during reflow. Illustrations that lie within one line of a paragraph are classified as character surrogates. A character surrogate is an illustration that functions as a text character. Character surrogates are treated as text elements during reflow. Illustrations that lie within the bounding box of a paragraph, and which vertically overlap with two or more initial lines, and which are to the left of all the characters in those lines, are classified as “illuminated letters.” Illuminated letters are reflowed at the upper left of the paragraph, with the text elements of the paragraph flowed to the right and below the illustration.
Illustrations that lie directly above (or below) a paragraph are reflowed to lie directly above (or below) that paragraph. Illustrations that do not fit within the reflow bounding box are scaled to fit within that bounding box.
The invention can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention can be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention can be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program can be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language can be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory. Generally, a computer will include one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits).
To provide for interaction with a user, the invention can be implemented on a computer system having a display device such as a monitor or LCD screen for displaying information to the user and a keyboard and a pointing device such as a mouse or a trackball by which the user can provide input to the computer system. The computer system can be programmed to provide a graphical user interface through which computer programs interact with users.
The invention has been described in terms of particular embodiments. Other embodiments are within the scope of the following claims. For example, the steps of the invention can be performed in a different order and still achieve desirable results.
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A method and computer program product for reflowing a PDL page without using the original application used to create the PDL page. The method and computer program product include receiving a page represented in a page description language, the page including a plurality of page objects, and changing one or both of a size of the page and a size of one or more of the page objects, while maintaining spatial relationships between the page objects.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to the oil and gas industry. The Abrasive Hydrojet Perforation Technology offers an effective means to communicate the wellbore with the target formation and to achieve more effective completion due to an increase of flow area, bypassing the damage in a near-wellbore zone and reduction of the compressive stresses The invention represents a new method of treatment of a near-well zone of the producing formation with a combination of chemical treatment.
[0002] It is known that flow from productive zones can be increased by slotting and chemical treatment. Slotting allows redistribution of the mechanical stresses in the near well zone, while chemical treatment allows increased productivity of the wells. However, the first method is very labor consuming and requires high costs. In order to shot three feet of the productive interval some time it is necessary to spend up to three hours of pumping unit operation, which is an expensive operation. The chemical action also treats the near well zone, but it requires a primary opening of the formation and does not remove a zone of support pressure which is a main reason of locking of the passages for fluid flow into the well. The first method is very efficient and increases the productivity of wells on average several times, however it is expensive. In order to provide maximum effectiveness or completely restore the potential productivity of wells, it is usually necessary to provide a subsequent treatment with formation-treating reagents.
[0003] Some of known solutions are disclosed for example in U.S. Pat. No. 3,966,922; patent document WO94/05898; SU 10472234; SU 1031263; SU 1167925; “Method Recommendations for Increase of Permiability of near Well Zone by Slot Loosening” by Ministry of Geology USSR, PTO “SEIMORGEOLOGIA”, L., 1984; I. N. Ivanov, et al “Flow-in of Fluid to Well with the Use of Various Methods of Opening of Productive Formations”, Geophysical Magazine, 1984, no. 5; V. A. Sidorovski “Opening of Formations and Increase of Productivity of Wells”, M., Ndera, 1978, P111; “Method of Recommendations of Increase of Permeability of near Well Zone with Slot Loosening”, Nii Geology Arctics, Mingeologii USSR, L. 1979.
[0004] The method disclosed in SU1167925 is the closest to the present invention. It is a combined method for the increase of productivity, which includes slotting of the well and cyclic acid formation treatment. The slotting is performed in accordance with known “classic” recommendations in order to obtain a maximum possible effect, while the cyclic acid treatment is performed also in accordance with the known method described in the above mentioned documents, for a depth which is not less than 5 diameters of the well, so as to attempt to completely use its possibilities without the consideration of the results of slotting or control of the results of each cycle. The cyclical “periodic” treatment of a well was performed by a reagent solution whose volume was determined from a mass and porosity of rock adjoining a shaft of the well, at a distance of approximately two diameters from the well. Each cycle of treatment is performed by pressing of a calculated volume of solution into the formation to be treated, which is preliminarily limited from above and from below by packers. The treatment in some sense is performed blindly, the results were evaluated in accordance with a change of productivity of the well. The cycles of treatment continued until the time when repetition did not lead to a change in productivity.
[0005] It has been shown from practice that this method which includes a complete slotting with a subsequent complete treatment with technological reagents has a universal action on the formation and provides an increase of well productivity, an equalization of a profile of advancement of a front of water pumped into a formation for maintaining of the formation pressure, an increase of the oil yield of the formation. Because of these advantages this method has been widely utilized. It also has been used during exploration and drilling of new wells. Moreover, it was made possible with this method to explore and efficiently use wells in low-production formations of Western Siberia in which the oil flow is less than 30 bbl per day. This method therefore is efficient. However, this method, similarly to the other methods has a limitation as to its possibility and efficiency. It is expensive, labor consuming and does not guarantee obtaining of the maximum possible increase of well productivity. The method is used without consideration of negative action of elevated stress concentrations, which are formed near the wellbore.
[0006] It is known that the maximum stresses in the near well zone are generated within one diameter of the well or approximately 0.6 ft., and the maximum stress directly adjoins the walls of the well (FIG. 1). The plastic zone in this case can be not considered, since in accordance with the calculation its width at the depth of 10,000 ft. is only 0.03 ft. It is also known that during the process of the drilling of wells, even after carrying out slotting, a zone of support pressure remains near it. The slotting removes only a part of these stresses, which is equivalent to a reduction of depth of the well approximately 1.5 times. During slotting at the depth of 10,000 ft. it is equivalent to a reduction of stresses to the depth of 6,600 ft. However, the mode and parameters of acid treatment (or treatment with other reagents, such as technological compositions) nowadays are determined without consideration of negative influence of the remaining stresses near the well. The zone of support pressure, which remains around the well, is not taken into consideration and parameters of treatment with technological compositions are calculated from the condition of action of a uniform supply of active technological solution per volume unit of a formation.
[0007] However, experimental observations and analytical investigations showed that the influence of zone of support pressure near the well is significant. If this influence is not taken into consideration, false conclusions can be made with respect to the productivity of the wells. Based on the results of the treatment, it is considered that a low oil yield from a formation can be explained by a week natural permeability of the formation itself, while a real cause is the reduction of permeability only within limits of the zone of support stresses, caused by stress concentration beyond the wellbore.
SUMMARY OF THE INVENTION
[0008] Accordingly, it is an objective of the present invention to reduce labor consumption and cost of treatment of a well, without a reduction of efficiency of treatment, time of use of wells, and gas/oil yield of productive formations.
[0009] In keeping with these objectives and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a method for increasing production of oil, gas and hydrogeological wells, which includes Abrasive Hydrojet Perforation Technology (AHPT) and a cyclical treatment of a near well zone with a formation treating reagent, with cutting of slots, determination of a productive zone, and a corresponding volume of a treating technological composition, and introduction (pressing through) of the volume into a formation to be treated, in which in accordance with the present invention the method is performed in two stages so that in the beginning a partial Abrasive Hydrojet Perforation of a near wellbore zone is performed so as to redistribute stresses, and then a remaining part of the support stresses is removed by a cyclical treatment of a well with a formation treating reagent with its control in accordance with the density of the formation to be treated and with a corresponding correction.
[0010] The following is a short summary of the benefits, improvements and the most promising applications of Abrasive Hydrojet Perforation technology:
[0011] The Abarsive Hydrojet Perforation Technology (AHPT) slotting provides a very precise, reliable and controllable method to establish a large inflow path between the cased borehole and the formation. The inflow area of an 8-in per foot dual slot is equivalent to 36 spf of 0.75-in shaped charge holes. Moreover, the pressure drop on AHPT slot is significantly less then on the areal equivalent set of perforated holes. In addition, the AHPT cutting process is much more robust in creating a low-resistant flow path, even with two strings of casing
[0012] AHPT slotting preserves the integrity of the cement bond. This can be critical for zonal isolation when the perforated intervals are in close proximity to water or a gas cap. The integrity of the cement sheath also increases the casing strength and resistance to failure.
[0013] The created AHPT slots simplifies the fracture initiation and therefore may significantly reduce the near wellbore problems (multiple fracturing, tortuosity, etc.). This reduces the chances of NWB screenouts during fracture stimulation and minimizes the choking non-darcy effect because of the tortuous path during production (esp., in gas wells).
[0014] AHPT slot geometry (with the penetration depth up to 4-10 ft) bypasses the near wellbore mud invasion zone and increases the drainage area. This suggests that AHPT slotting in clean, high permeability sands is the preferred completion method. If these clean formations require sand control, AHPT slotting can be used in combination with high rate water packs. For laminated formations, AHPT slots in combination with F&P should result in consistent negative skin completions.
[0015] AHPT cutting does not reduce the near wellbore strength of the formation, as does conventional shape charge perforating. Under some circumstances, this AHPT feature in combination with a larger created drainage area may allow a natural completion of formations that currently require sand control.
[0016] The slots modify the stresses in near the wellbore zone (relaxed in zone adjacent to the slots, and increased at the tip zone). Formations with strong stress-dependant permeability may encounters significantly reduced completion skin. Moreover, for deep and relatively hard formations. slotting may achieve compressive fracturing in the near wellbore region that results in a significant permeability increase at a distance of several slot diameters and dramatic reduction of the near wellbore conversion pressure drop. In gas wells it will reduce (or completely eliminate) sometimes very large non-darcy skin.
[0017] In order to optimize the method, the partial Abrasive Hydrojet Perforation is performed by cutting slots only in a surrounding column, cement layer and a part of the productive zones of the fromation.
[0018] This method allows cutting slots in a thin productive zone and in the case when the productive layer is not far away from water horizons. Abrasive Hydrojet Perforation is preformed by fluids, which includes water and quartz sand. This allows preserving the integrity of cement and leads toward higher penetration into the formation compared to other technology and methods (conventional perforation, hydrofracturing).
[0019] The technology can be divided into surface and underground equipment (FIG. 2). Underground equipment includes an engine with nozzles, which is connected to surface pumping units (FIG. 3). For Abrasive Hydrojet Perforation, hydrojet perforators ( 11 ) are used; for single slotting the perforator is used with 4 nozzles. Nozzles are located 180 degrees across from each other. The distance between nozzles is around 4″. The abrasive fluid is recycled all of the time during the process. In addition underground equipment includes (FIG. 3): underground engine ( 8 ), engine switch ( 9 ) and hydrojet perforator ( 11 ). This equipment can slot in one session three intervals with the approximate length of 3 ft. each. After that perforators must be changed. Description of the slotting technique is shown on (FIG. 4).
[0020] Surface equipment includes (FIG. 2) pumping units, mixer blender for sand/water, block manifold, filters and connectors. Pumping units for Abrasive Hydrojet Perforation can be used with the following characteristic: 5,00-10,000 psi, depending on well depth, and continuous working capacity of 6 hours.
[0021] Abrasive fluids prepared in blender. Filters are used to filter fluids and separate water for the recycling process. Quartz sand can be used as the abrasive material with quartz consumption not less then 50%.
[0022] During the Abrasive Hydrojet Perforation it is preferable preliminarily to determine the porosity and permeability of the production formation of the near wellbore zone, and the depth of the zone of support stresses, and to perform the subsequent treatment in dependence on the porosity and depth.
[0023] In particular, when the rock has a porosity of approximately 15% and higher, the Abrasive Hydrojet Perforation is performed at the depth of 1-1.5 well diameters, with the porosity of less than approximately 15% the Abrasive Hydrojet Perforation is performed at the depth not less than four well diameters.
[0024] In the first case, this reduces the time and cost of treatment almost in half, and in second case it guarantees achieving of the maximum possible effect. Moreover, during a subsequent cyclic treatment with technological reagents in order to increase permeability of the zone of remaining support stresses, between each treatment a radius of a zone of support pressure and a maximum acting stress in it are determined and the treatment is performed on a part of the formation which adjoins the well, including a zone of the support pressure. After each cycle of treatment, a change of density (permeability) of the formation in the zone of support pressure is controlled.
[0025] In order to optimize the method, the treatment is stopped when the density of the formation in the zone of support pressure is reduced by a predetermined value, which is determined in accordance with the formula:
Δρ≧ K ρ(σ y −γ·H )/ E,
[0026] wherein K is a factor of efficiency of treatment,
[0027] ρ is the density of the formation of a not disturbed formation at the depth, lb/ft 3
[0028] σ is the maximum stress acting in the zone of support pressure MPa,
[0029] γ is the specific weight of rock of the formation, lb/ft 3 ,
[0030] E is an elasticity modules of formation rock, MPa.
[0031] It is also proposed in accordance with the present invention to use a technological solution with an acid reaction of flow, which interacts with a clay component of colmatating portions and a matrix of rock of a productive formation, whose composition is selected in accordance with the nature of the rock of the productive formation of a near well zone.
[0032] In particular, with a terrigen collector of the productive formation, the technological solution is a solution of NaHSO 4 ×H 2 O and/or K 2 S 2 O 7 and/or (NH) 4 S 7 O 6 with concentration of 4-7%, with additions of anion active surface active substances or mixture of anion active and noionogenic surface active substances within the concentrations 0.5-2%.
[0033] If in a terrign collector, there is a carbonate component more than 30% and if there is a carbonated collector of the productive formation, the technological solution can be a solution of NH 2 SO 4 H with addition of anion active surface active substances or a mixture of anion active and non ionogenic surface active substances within the concentrations 02-04% and polyphosphates within the concentration 0.1-0.2% or a solution of CH 3 COCl with concentration 6-12% with admixtures of anion active surface active substances or a mixture of anion active and non ionogenic surface active substances within the concentration 0.5-1% or polyphosphates within the concentrations of 0.1-0.2% and as polyphosphates, there are used in Na 5 P 3 O 10 and/or Na 2 [Na 4 (PO 3 ) 6 ].
[0034] In accordance with a further advantageous feature of the present invention, the formation treatment fluid (technological solution) is formed directly in a well within an interval of a formation to be treated, for example by enclosing of chemical agents for preparation of a solution into a transport package, transporting the package to the formation to be treated, and then removing the package for example by its dissolution with a solution in the well or by supplying of a dissolving liquid.
[0035] The transporting package can be formed as a micro container or capsule with a dissolvable enclosure formed, for example as a water soluble polyethylene film. The container can be also composed of a binding material, for example starch which is water soluble without the residues and consequences. Containers can be formed as balls or cylinders. Thus, the new features of the present invention include a combination of operations, such as performance of the method in two stages with a primary controlled partial Abrasive Hydrojet Perforation and a subsequent controlled and regulated cyclical treatment of a well with a formation-treating agent, cutting of slots only in a surrounding column, a cement layer and a part of the rock of the collector immediately adjoining the well, preliminary determination of porosity of the rocks of the productive formation of the near well zone and a depth of a zone of support stress, and correction of a further treatment depending on the porosity and depth, determination of a radius of zone of support pressure and a maximum acting stress in it before each cycle of the formation treatment, carrying out of the treatment of all parts of the adjoining formation to the well including a zone of support pressure, controlling of a change of density (permeability, porosity) of rocks in the zone of support pressure after each treatment, stopping of the cyclical treatment when density of the formation in the zone of support pressure is reduced by a predetermined value, change of volumes (radii) of a mass which is treated in stages, selection of compositions of technological solutions and their preparation directly in a well in an interval of a treating formation. These features provide an unexpected result, which is a significant reduction of labor consumption and cost of the method without a reduction of efficiency of treatment and long-term stabilization of the obtained effects. These results are unobvious and inventive.
[0036] The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] [0037]FIG. 1—description of σ in Abrasive Hydrojet Slotting Perforation
[0038] [0038]FIG. 2—surface equipment used for Abrasive Hydrojet Slotting Perforation
[0039] [0039]FIG. 3—underground equipment used for Abrasive Hydrojet Slotting Perforation;
[0040] [0040]FIG. 4—detailed description of underground equipment used for Abrasive Hydrojet Slotting Perforation;
[0041] [0041]FIGS. 5., 6 , 7 are views showing a distribution of stresses in a near well zone before the beginning of a cyclical treatment, after a first cycle of treatment, and after the end of treatment correspondingly.
[0042] In the drawings the following symbols are utilized:
[0043] σ x σ y are a vertical and a horizontal stress,
[0044] σ y1 is a remaining maximum stress in a zone of support stresses before a beginning of a formation treatment (after a partial Abrasive Hydrojet Perforation),
[0045] σ y2 is a remaining maximum stress in a zone of support of stresses after a first cycle of formation treatment,
[0046] γH is a remaining maximum stress in a zone of support stresses after the end of formation treatment,
[0047] r 1 is a radius zone of remaining support stresses before the beginning of formation treatment (after a partial Abrasive Hydrojet Perforation),
[0048] r 2 is a radius of a zone of remaining support stresses after a first cycle of formation treatment,
[0049] r 3 is a radius of zone of reduced support stresses around the well after a first cycle of formation treatment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] It is known that a maximum stress in a near wellbore zone within one diameter of the well shown in FIG. 1 is approximately 0.6 ft.
[0051] The maximum stresses directly adjoin the walls of the well. In the present invention it is permissible not to consider a plastic zone, since in accordance with calculations its width at the depth of 10,000 ft. is only 0.4″
[0052] It is therefore proposed to reduce and redistribute the maximum stresses without a complete cutting of an unloading slot. This significantly accelerates and reduces the cost of the method. Then it is suggested to remove the remaining part of stresses in the zone of support pressure with another method (formation treatment) with labor consumption which is lower than usual. As a result, a desired corridor for movement of useful fluids into the well is formed in a reliable and less labor consuming method.
[0053] The corresponding operations of the method include the following sequence.
[0054] Before the beginning of works, porosity and density of a formation is evaluated by geophysical methods. For example the porosity is determined by a neutron logging, while density is determined in accordance with a density logging. If the porosity is higher than approximately 15%, the speed of movement of the perforator is selected to be 1.5 hours for 3 ft., instead of the conventional three hours for 3 ft. In this case, a surrounding pipe, cement and a main part of the area of increased stresses will be cut through, and directions for pumping of a formation treatment solution are created. The solution, in addition to a conventional dissolution of cementing substance of the productive formation, performs pressurization of rock of the productive formations and therefore increases support stresses.
[0055] If the porosity of rock is less than approximately 15%, the Abrasive Hydrojet Perforation is performed in accordance with the traditional method, with a speed of cutting of the slot about three hours for 3 ft. After this, because of the formation of a great draining surface a more reliable depressurization of rock in the zone of support pressure is performed, and a maximum reduction of stresses in the near well zone is obtained.
[0056] The formation treating reagent can be for example a solution of hydrochloric acid (for carbonate rock and for terrigen rock with a significant content of carbonate cement).
[0057] Initially, the remaining stress-deformed condition of the rock in the near well zone is evaluated, and based on it; a pattern of distribution of support stresses is determined as represented by a curve 1 in FIG. 5.
[0058] The stress condition is evaluated by experimental methods. In wells which do not have surrounding tubes, it is necessary to use electrometric and ultrasound methods. In wells, which are provided with surrounding tubes, it is possible to use a method of radioactive (density and neutron) logging. It is also possible to use analytical methods for the calculation of parameters of the zone of support pressure.
[0059] Based on the evaluation of the stress condition, a zone of support loads and a compaction of rocks with radius r 1 (FIG. 5) is determined and a volume of rocks is calculated, within limits of a cylindrical column near a well, which are to be subjected to a preliminary treatment V r 1 =π( r 1 2 −r 2 2 ) m,
[0060] wherein m is a thickness of a formation-collector,
[0061] r c is a radius of the well.
[0062] In correspondence with this volume, a volume of an acid solution for pumping (pressing through) into a near well zone of formation is determined:
V
p
1
=V
r
1
·n,
[0063] wherein n is the porosity of the rock of a formation-collector.
[0064] This portion of solution is pumped into the well, pressed into a near well zone of formation for action on the zone of support pressure. As a result of this action, dissolving of both the cement of rock and the rock itself is performed. When the dissolved mass is withdrawn, density of the rock and action in this zone of stresses is reduced. The evaluation of the obtained effect of depressurization is performed by the geophysical methods. The efficiency of treatment with a first cycle can be insufficient. FIG. 6 shows that as a result of the first cycle of action, a certain effect is obtained, which is a reduction of maximum value of stresses to the value σγ 1 <σγ 2 . Near the wall of the well, a ring of reduced stresses with a radius r o is obtained. However, within the interval r 2 stresses continue to act, which exceed initial stresses of the untouched mass.
[0065] In this case a second cycle of pumping is performed in accordance with the same or reduced parameters. A change of quantity of the pumped solution to increase the volume Vp 1 is necessary in the case if an exterior radius of a ring of compaction is increased r 2 >r 1 .
[0066] After the second cycle of action, again a control of efficiency is performed and the necessity of a subsequent treatment of the zone is determined.
[0067] An ideal result of the treatment is a complete removal of a “splash” of support loads when in the vicinity of a well a “funnel” of stress “is formed, which is characterized by a pattern of monotonous increase of stresses and density of rocks from a wall of the well into a depth of the mass as shown in (FIG. 7).
[0068] The achievement of this pattern is not always necessary. Even a partial depressurization of the rock in the zone of support pressure can provide a sufficient effect of increase in well productivity. Therefore, a factor of efficiency of treatment K is introduced, which characterizes a given critical level, in accordance with which it is necessary to reduce stresses acting in a support zone.
K = δ y 1 - δ y 2 δ y 1 - γ H ,
[0069] The value K>1 corresponds to a complete unloading of rocks in the zone of support pressure as shown in FIG. 7. Values 0<K<1 correspond to a partial unloading of rocks as shown in FIG. 3. In practice the coefficient K is determined experimentally, but as a rule it cannot be equal to 1.
[0070] Removal of a “threshold of compaction” in the zone of support pressure in certain conditions increases the productivity of the well, not more than by 15%, which is summed with the effect of Abrasive Hydrojet Perforation.
[0071] As for the selection of concrete composition of technological solutions for this treatment, it should be mentioned that for treatment of a terrigen collector of productive formation, there are utilized solutions of NaHSO 4 ×H 2 O and/or K 2 S 2 O 7 and/or (NH) 4 S 7 O 8 with concentration 4-7% with additions of anion active surface active substance or a mixture of anion active and non ionogenic surface active substance with concentrations 0.5-2%. The destruction of clay colmatating regions with this technological solution is performed by disturbance of coagulating contacts between clay aggregates of colmatating regions, dissolution of admixtures, cementing sand, and dealkylization of alumosilicates which form carcasses of clay aggregates.
[0072] When in a terregin collector there is a carbonate fraction of higher than 30% and when there is a carbonate collector of the productive formation, then a technological solution with an acid reaction can be a solution of NH 2 SO 3 H with admixtures of anion active surface active substance and a mixture of anion active and non iongenic surface active substance with concentration 0.2-0.4% and polyphosphates with concentration 0.1-0.2% or a solution of CH 3 COCl with concentrations 6-12% with admixtures of anion active surface active substance or a mixture of anion active and non ionogenic surface active substance with concentration 0.5-1% and polyphosphates with concentration 0.1-0.2%, and as polyphosphates Na 5 P 3 O 10 and/or Na 2 [Na 4 (PO 3 ) 6 ] are utilized.
[0073] Sulphamine acid actively dissolves carbonate rocks. When an acethyle chloride is dissolved in water, a mixture of asetic and hydrochloric “acid is formed in a condition of active temperature increase:
CH 2 COCI+H 2 O—CH 3 COOH+HCI+ΛQ↑
[0074] which also provides a dissolution of carbonates in a thusly formed rock area.
[0075] The utilization of agents of complex-forming action in the composition of a carrier liquid in the case of Na 5 P 3 O 10 and/or Na 2 [Na 4 (PO 3 ) 6 ] stabilizes the technological solutions and prevents a secondary deposition of calcium in the case of very low concentrations which are not sufficient for binding of deposited cations into soluble complexes. The stabilization effect of such very small admixtures is connected with adsorption processes. Phosphate and ions are adsorbed on seeds or growing crystals, block active centers and therefore prevent precipitation of salts. As a result of laboratory tests for dissolving of carbonate rocks with such technological solutions with an acid reaction, optimal values of polyphosphates in condition of neutralization of solutions are determined as 01-02%.
[0076] The above mentioned technological solutions are preferably prepared directly in the treated formation. For example, powder chemical agents for preparation of solution are filled in a transporting package, the package is delivered into an interval of treated formation, and then the transporting package is removed, for example by its dissolution with a dissolving liquid supplied into the well. The powder mixture is made from components, introduced into containers (capsules or mini containers) with soluble enclosure, and transported to the interval of intersection of productive formation, preliminarily separating it from lower and upper layers with a packer. Then, dissolution of container is performed, or a solvent for capsule casing and a solvent for agents are introduced into the productive layer. When the solution is ready, the inter-pipe space is cut off by packers, and the solution is pressed into the formation. This leads to an economy of reagents, their more accurate dosage, simplification of requirements for a material of column and a pumping mechanism, elimination of corrosion, etc. This increases the efficiency of treatment by more accurate composition of the treating fluid in the productive treated formation, reduces the consumption of agents, and protects equipment of action of chemical agents in the fluid. This approach significantly reduces the volume of required agents, increases the quality of treatment by more accurate correspondence of real working formation-treatment composition to a calculated composition, reduces requirements to equipment and increases its service life.
[0077] The transporting package can be formed as a mini container, such as capsules with a soluble enclosure, in particular with the use of starch, in form of balls. The calculated quantity of balls is thrown into the well and then water is poured on them. Starch is dissolved in water without residual and without any harm.
[0078] The method in accordance with the present invention is illustrated by the following examples:
EXAMPLE 1
[0079] Initial conditions. A treatment of an operating well with a diameter 8″ is performed, with a carbonate collector of 164 ft. at the depth 6,562 ft. It is known that an elasticity module is E=3×10 5 MPa, specific weight of rock γ=125 lb/ft 3 . The well has an open shaft, and before treatment it has a yield 28.3 bbl/day.
[0080] Performed operations. It has been determined by geophysical methods that the porosity of the productive formation is 10%, density of the formation in a zone of support pressure p=193.5 lb/ft 3 . Taking this into consideration, speed of cutting 0.45 hour per 1 ft. r and concentration of abrasive fluid 0.06 lb/ft 3 are selected. The composition of abrasive is a sand with grain size 0,008-0,04″ and quartz content not less than 50%.
[0081] The ground equipment is installed which provides a pressure of the abrasive fluid 4,800 psi a predetermined concentration of abrasive fluid, washing of well, collection of stone material, and receipt of productive fluid. Then the underground equipment is connected, in particular a perforator engine with a perforator adjusted to the predetermined cutting speed 0.43″/minute. Then the underground equipment is lowered to the depth 6,562 ft. and after adjustment of the equipment of the depth, a slot cutting with the speed 4″/minute is performed. The cutting is performed approximately in (0.45×164=73.8 hours.
[0082] The Abrasive Hydrojet Perforation is performed only in approximately 75 hours instead of 150 hours in a known method. After the partial slot treatment, the productivity of the well increased over 60 bbl/day.
[0083] The required reduction of density of the rock in the zone of support pressure was calculated
Δρ = 1 × 6562 × ( 80 × 10 6 - 1250.125 ) 3.10 ″ = 1.75
[0084] The volume of rock to be treated is determined Depth of slotting not less then four diameters equivalent to 32″, open slotting 4″, then we can calcutae the volume of the slot:
V= 32×4×164=132 bbl.
[0085] Where productive layer in the formation equal 164 ft. as well as a required volume of acid:
132×0.1−3.2=10 bbl.
[0086] 3.2—volume without slotting
[0087] 0.1—porosity of the collector
[0088] Then 10 bbl. of acid is pumped into an interval of treatment, it is pressed into the formation, and after the reaction the products of reaction are removed by draining. Then the geophysical observations were performed, and it was determined that the stresses in the zone of support pressure reduced to 60 MPa, while a radius of the zone of support pressure increased to 1.6 ft. The obtained reduction of permeability is determined as follows:
Δρ = ρ ( δ y 1 - δ y 2 ) E , Δρ = 6562 ( 80 - 60 ) .10 6 3.10 ″ = 0.84
[0089] The quantity of acid for the second cycle of treatment is calculated as follows.
Δρ=0.84 lb/ft. 3 <1.75 lb/ft. 3
[0090] After this, another treatment of the productive interval was performed. The geophysical investigations were carried out, and an obtained reduction of density of the rock in the zone of support pressure was determined. A complete removal of stresses in the zone of support pressure made possible an increase in the productivity of the well even more than 20%.
[0091] The cost of the second stage of the method, which is the formation treatment, and the common time of two cycles was only about 6 hours with an insignificant cost and the use of relatively simple equipment.
[0092] Therefore, the total time of realization of the method in the given concrete case was correspondingly approximately 80 hour, which is approximately ½ when compared with the traditional methods of increasing the productivity of wells. The efficiency of treatment and the time of maintaining the obtained yield are at least identical.
[0093] The main advantage of the proposed method is a significant reduction of labor consumption and the cost of the method, with maintaining of increased efficiency. This is achieved mainly by a subdivision of the method into two controlled and regulated stages, and by optimal distribution of labor consumption and cost of the treatment between the two stages. Simultaneously, the method includes additional technological features, which increase its efficiency, namely a new selection of agents and preparation of a technological solution directly in the well.
[0094] The method takes into consideration that the zone of support pressure adjoining the well is the most responsible in the system of filtration of fluid from the formation into the well. The quantity of flowing fluid (gas) per unit of filtering area is increased in the second power when it approaches to the well. The highest intensity of streams is in this zone. This is the reason for the maximum “dirtying” of rocks with asphalt-resin and other deposits, which substantially reduce the productivity of the well.
[0095] It is therefore extremely important to reduce the tendency to accumulation of destroyed particles of rocks and drilling solution, to eliminate the zone of dirtying and near well zone which is subjected to the action of support pressure and is the most close to the bare zone which is the zone of support pressure.
[0096] The proposed invention significantly reduces labor consumption and costs of works for increasing productivity and unobjectionable movement of fluids in this zone, which explains cleaning of filtering passages and therefore long-term action of the obtained effect of treatment.
[0097] In FIG. 2 reference numeral 1 identifies a mouth of the well with a fountain equipment, reference numeral 2 identifies filters for cleaning of a pulp, reference numeral 3 identifies a block of manifolds, 4 is a pump aggregate, 5 is a sand mixing aggregate and 6 is a containment.
[0098] In FIG. 4 reference numeral 1 identifies a chemically treated part of a productive layer with worsened collector properties, while reference numeral 3 identifies a treated part of the productive layer with good collector properties. The other elements shown in FIG. 1 are: a perforator 2 , packers 4 , pumping compressor pipes with an engine of the perforator 5 , non permeable rock 6 , a productive layer with good collector properties 7 , a cut through part of the productive layer with good collector properties, a productive layer with worsened collector properties 9 , a cut through part of the productive layer with worsened collector properties, a tail part 11 and a plug 12 .
[0099] 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 constructions differing from the types described above.
[0100] While the invention has been illustrated and described as embodied in the method of increasing productivity of oil, gas and hydrogeological wells, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in anyway from the spirit of the present invention.
[0101] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A method of increasing the productivity of oil, gas and hydrogeological wells has the steps of performing a slot unloading, providing a cyclical treatment of a near well zone with a formation-treating substance, with a use of cutting slots, determining a region to be treated, selecting a corresponding volume of a treating technological composition, and introducing the volume into a formation to be treated, and subdividing the method into a two stages including a first stage performed by a partial slot unloading of a near well zone so as to remove a main part of support stresses, and a second stage of removing a remaining part of support stresses by a cyclical treatment of the well with a formation-treating substance with control by the density of the rock to be treated and performing a corresponding correction.
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BACKGROUND
[0001] This invention relates to data mining and in particular to evaluating data from a database producing results similar to those of using on-line analytical processing (OLAP) but in a far more computationally efficient manner.
[0002] In problems such as in extracting market data from a database, data is often organized in dimensions that are in a hierarchy. For example, records are often assigned ID's and the records will have data for various attributes that a user may wish to track. An example of a dimension hierarchy might be age. The hierarchy of age can have levels as young, middle, and old. Within each of these levels of young, middle and old can be various numeral age groupings or sublevels such as young being 18-25 or 25-30; middle being 30-40 and 40-55; and old being 55-65 and 65 and over, and so forth. A second hierarchy might be income, with income having different levels and sublevels. Competing approaches to evaluate cross tabulations of age and income in this example use techniques where the number of computations is related to the number of dimensions and number of levels or sublevels of the data. For very complex or large number of dimensions, the computations increase at an exponential rate.
SUMMARY
[0003] According to an aspect of the present invention, a method of producing a cross tabulation, includes issuing a plurality of queries to a database, the queries being for multiple sublevels of data for multiple dimensions of data associated with records in the database to provide a sublist of sorted record identifiers for each one of the queries and determining occurrences of intersections of levels of one dimension with levels of another dimension of the data associated with records in the database by traversing the sub-lists to detect intersections of the dimensions.
[0004] According to a further aspect of the present invention, a computer program product resides on a computer readable medium. The computer program product is for producing a cross tabulation structure. The computer program includes instructions for causing a computer to issue a plurality of queries to a database, the queries being for multiple sublevels of data for multiple dimensions of data associated with records in the database to provide a sublist of sorted record identifiers for each one of the queries, determine occurrences of intersections of levels of one dimension with levels of another dimension of the data associated with records in the database by traversing the sub-lists to detect intersections of the dimensions, and indicate in a cross-tabulation structure each time an intersection of one dimension with levels of another dimension of the data is found.
[0005] According to a further aspect of the present invention, an apparatus includes a processor, a memory coupled to the processor, and a computer storage medium. The computer storage medium stores a computer program product for producing a cross tabulation structure. The computer program includes instructions which when executed in memory by the processor, causing the apparatus to issue a plurality of queries to a database, the queries being for multiple sublevels of data for multiple dimensions of data associated with records in the database to provide a sublist of sorted record identifiers for each one of the queries, determine occurrences of intersections of levels of one dimension with levels of another dimension of the data associated with records in the database by traversing the sub-lists to detect intersections of the dimensions and indicate in a cross-tabulation structure each time an intersection of one dimension with levels of another dimension of the data is found.
[0006] One or more aspects of the invention may provide one or more of the following advantages.
[0007] The process allows the user to specify the dimensions in a query statement, thus allowing the user to specify 2 dimensions, 3 dimensions, and so forth. The process executes sets of queries for each specified dimension only once, while construction of each structure is accomplished by matching/merging sorted ID lists. The process performs pre-aggregation of data for fast display/drill-down by computing a structure quickly after some initial sorting operations. The process can work over multiple dimensions of data, where it is needed to aggregate data over multiple dimensions for analysis while avoiding an exponential growth situation. The algorithm performs a very efficient 1-pass through the data.
[0008] The process provides a number of performance improvements over competing processes. For instance, the speed of calculations is based on the sum of the number of levels over all dimensions or the sum of the most granular number of levels for each dimension if the hierarchy can be rolled up from lower levels.
[0009] For a single-dimension query, the computation is of the order (n log n), where n is the number of rows of data being processed, assuming that the data is not sorted. For calculating multiple dimensions, the calculation is of the order of (n log n) times m, where m is the number of levels across all dimensions (or the number at the most granular levels across all dimensions if the hierarchy can be rolled up from lower levels). If the data is returned from a database with the fields already sorted, the calculation complexity is of the order (n×m). This approach can be 10 to 100 times faster than competing approaches which have a calculations on the order of n*the number of complex queries=f (number of dimensions and levels).
[0010] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a block diagram of a computer system accessing a database.
[0012] FIG. 2 is a block diagram an exemplary record in the database.
[0013] FIG. 3 is a flow chart of a cross-tabulation technique.
[0014] FIG. 4 is a block diagram of a table.
[0015] FIG. 5 is diagram depicting sorted lists and cursors.
[0016] FIG. 6 is a diagram depicting a two-dimension cross-tabulation structure.
[0017] FIG. 7 is a flow chart of a merging technique.
[0018] FIG. 8 is a diagram depicting a three-dimensional cross-tabulation structure.
DETAILED DESCRIPTION
[0019] Referring now to FIG. 1 , a computer system 10 includes a CPU 12 , main memory 14 and persistent storage device 16 all coupled via a computer bus 18 . The system 10 also includes output devices such as a display 20 and a printer 22 , as well as user-input devices such as a keyboard 24 and a mouse 26 . Not shown in FIG. 1 but necessarily included in a system of FIG. 1 are software drivers and hardware interfaces to couple all the aforementioned elements to the CPU 12 .
[0020] The computer system 10 also includes marketing automation/Campaign Management software 30 that resides in storage 16 and which operates in conjunction with a database 32 . The marketing automation/Campaign Management software 30 supports various types of campaign programs. The marketing automation/Campaign Management software 30 allows a user to quickly form cross-tabulations of records in the database using a cross-tabulation process 40 . The marketing automation/Campaign Management software 30 is shown residing in storage 16 but could reside in storage in server 28 as part of a client-server arrangement, or can be configured in other manners.
[0021] Referring now to FIG. 2 , a data set includes a plurality of records with record 33 being illustrative. The record 33 can include an identifier field 34 a, as well as one or a plurality of fields 34 b corresponding to values that may be used in the marketing automation/Campaign Management software 30 . The record 33 also includes a plurality of result fields 35 that are used by a modeling process (part of the marketing automation/Campaign Management software 30 or independent software on either the computer system 10 or the server 28 ) to record scores for the record 33 . The record 33 can also include key fields (not shown) that are used to join and navigate between database tables (not shown). Typically, for each of the records, one (or more) of the fields would be a primary key for that record in the record's primary table and the others would be secondary keys for tables that it might be joined to according to some characteristic or search request.
[0022] Referring to FIG. 3 , cross-tabulation process 40 produces an n×n (e.g., a 4×4 cube or cross-tabulation structure) ( FIG. 6 ) of counts of occurrences of records 33 in the database 32 that have intersecting levels of data for different dimensions of data (fields) in the records 33 .
[0023] However, the algorithm does not require the number of sublevels in each dimension to be equal (i.e., it works equally to generate an n×m structure). In an illustrated embodiment, database 32 stores records 33 of potential contacts for the marketing automation/Campaign Management software 30 . The records 33 have fields that specify an audience (e.g., customer ID), and for each audience ID, other attributes (e.g., age and income) of the customer. Other examples of different audiences (e.g., household, account, customer, business), types of data, or different types of records can be used.
[0024] The process 40 initializes 41 a indices m and n to m=1 and n=1 and issues 41 b a master query to retrieve a list of unique record ID's, e.g., Customer ID's. The process 40 issues 42 , the queries of the form, Select <Audience ID(s)> from <DB table> where <query condition> order by <Audience ID(s)>″ to the database 32 to retrieve lists of Customer IDs that satisfy each of the queries. The <query condition> in each query is based on the boundary conditions for each of the levels or sublevels of a dimension. The details in the flow chart of issuing the query is illustrative only to convey the sense that in one approach multiple queries are issued for the first dimension and thereafter multiple queries are issued for the second dimension and so forth. Other arrangements can be used of course.
[0025] In the example to be described, a count of customers with certain ages and incomes is desired. The query set can be organized to search the database to retrieve Customer ID's over sublevels of ages and incomes, e.g., with age and income in this example each having four sublevels. The queries in this case might be:
Select Cust_ID from TableX where Age<25 order by Cust_ID Select Cust_ID from TableX where Age>=25 and Age<35 order by Cust_ID Select Cust_ID from TableX where Age>=35 and Age<50 order by Cust_ID Select Cust_ID from TableX where Age>=50 order by Cust_ID Select Cust_ID from TableX where Age<18 order by Cust_ID Select Cust_ID from TableY where Income<25000 order by Cust_ID Select Cust_ID from TableY where Income>=25000 and Income<50000 order by Cust_ID Select Cust_ID from TableY where Income>=50000 and Income<75000 order by Cust_ID Select Cust_ID from TableY where Income>=75000 order by Cust_ID
[0035] These queries return record identifiers, e.g., Customer ID's in a form of a list that are sorted 44 by Customer ID 14 into a like plurality of sub-lists. In general, sorting is part of the process performed by the database returning results from the queries. Alternatively, the sub-lists that returned can be sorted using any efficient sorting technique. The process merges 46 the returned lists according to intersections between age and income (dimensions of data in the sub-lists) by scanning the sub-lists to produce count information that is used to populate a cross-tabulation structure ( FIG. 6 ) to indicate how many records exist in each combination of age and income sublevels. While the database could contain a very large number, e.g., a billion or more rows or records, by applying the process 40 the results are obtained quickly.
[0036] In the illustrative embodiment of building a 4×4 cross-tabulation structure, the process 40 issues 42 four queries to produce sub-lists of customer ID's that are in age bracket 1 , customer ID's that are in age bracket 2 , customer ID's that are in age bracket 3 , and customer ID's that are in age bracket 4 . The process also issues 42 four additional queries to produce sub-lists of customer ID's that are in income bracket a, customer ID's that are in income bracket b, customer ID's that are in income bracket c, and customer ID's that are in income bracket d. The total number of queries in this example is 8, which is one query for each age bracket and one for each income bracket. There is no need for the number of brackets for each dimension to be the same as they are in this example. Ideally, each list of customer ID's are already sorted by the database. Based on those 8 queries, the process sorts 44 if necessary and finds 46 the cross tabulation between qualifying age and income and populates the 4×4 cross-tabulation structure ( FIG. 6 ) as further explained below.
[0037] Referring to FIG. 4 , the database 32 (exemplary depiction) has records corresponding to 8 customers with customer ID's A-H and these customers have ages and incomes that fall within groups 1-4 and a-d as illustrated. Thus, customer A has an age in sublevel 1 and an income in sublevel b, customer B has an age in sublevel 2 and an income in sublevel c and so forth.
[0038] Referring now to FIG. 5 , the process 40 produces a master list 62 of all the customers here A-H and issues a query to return a sub-list 64 a of all Customer ID's that have ages that fall within sublevel 1 (which are Customer ID's A, C, and F). The process issues a second query to return a sub-list 64 b of all Customer ID's that have ages that fall within sublevel 2, (which are Customer ID's B and E), a third query to return a sub-list 64 c of all Customer ID's that have ages that fall within sublevel 3, (which are Customer ID's D and G), and fourth query to return a sub-list 64 d of all Customer ID's that have age that fall within sublevel 4 (which is Customer ID H).
[0039] A second set of queries is issued for income, the second dimension of the structure. The second set has a fifth query to return a sub-list 66 a of customer ID's for Income for “sublevel a” which are Customer ID's C and E. A sixth query is issued to return a sub-list 66 b of customer ID's for income for “sublevel “b, which are Customer ID's A and D, a seventh query returns a sub-list 66 c of customer ID's for income for “sublevel c”, which are Customer ID's B, and F and an eighth query is issued to return a sub-list 66 d of customer ID's for income for “sublevel d”, which are Customer ID's G and H.
[0040] Thus, between the two sets of queries (one set for age and one set for income), 8 queries are issued since each dimension of age and income has 4 sublevels. The number of queries issued is the sum of the number of sublevels, not the product. The sorted lists 62 , 64 a - 64 d and 66 a - 66 d are indexed by cursors or pointers 63 , 67 a - 67 d and 69 a - 69 d respectively.
[0041] Referring now to FIG. 6 , the process 40 merges 46 those lists by looking for intersections and thus generates a two dimensional array 80 having as dimensions the sublevels 1, 2, 3, 4, for the dimension “age” and the sublevels a, b, c and d for the dimension “income.” The process 40 produces an n×n structure (e.g., 4×4) where n is the number of sub-lists for each dimension. Thus, each cell of the structure 80 is an intersection corresponding to the sublevel of each dimension, age and income. The cell is populated with a value that represents the number of times that there was an intersection (common Customer ID) between a sublevel of age and a sublevel of income.
[0042] Referring to FIG. 5 and FIG. 7 , scanning or merging 46 of the sub-lists is accomplished by initializing 46 a the cursors 63 , 67 a - 67 d and 69 a - 69 d at the top of each of the sub-lists 62 , 64 a - 64 d and 66 a - 66 d respectively to the value one ( FIG. 5 ). The merging process 46 also initializes indices of the lists 64 a - 64 d and 66 a - 66 d to the value one, which in FIG. 7 are represented as dimension n (age, income) and sub-lists i, where n=2 and i=4 (for both dimensions). Initially the cursor 63 for list 62 points to a location where the first sorted ID (value Customer ID “A” in this example) is stored in the master list. The cursor 67 a at list 64 a in this example also points to a location where the value Customer ID “A” is stored in the sub-list 64 a representing those customers that have an age that falls in age sublevel 1. The cursor 67 b at list 64 b in this example points to a location where the value Customer ID “B” is stored and so forth.
[0043] The process 46 iterates over the lists in the first dimension to find the Customer ID “A” by reading 46 b the entry at the top of a first list comparing 46 c it to the current value in the master list and incrementing the index of the list being examined 46 d until the value Customer ID “A” is found. Finding that occurrence ends the loop if the lists are mutually exclusive, otherwise, an indication of a match is stored and the value of i is incremented to check the remaining lists. The process 46 stores the indication that list 64 a had the value of Customer ID “A” and increments 46 f the value “n” to find the occurrence of A in the second dimension, e.g., sub-lists 66 a - 66 d corresponding to income. The process loops through those lists till it finds Customer ID “A” in sub-list 66 b. Finding of Customer ID A in both dimensions is an intersection of those two dimensions (Age and Income) so that the cell (1,b) in the two dimensional array 80 , in the simplest case, is incremented 46 h to have a value of “1” indicating that there was a intersection between income sublevel b and age sublevel 1. In variations, computations other than count can be calculated (e.g., min, max, average, sum, etc. of some other attribute or field).
[0044] After the Customer ID “A” is found in all dimensions (here two) the cursors for the sub-lists (here sub-lists 64 a and 66 b ) where A was found are incremented 46 i. The cursor 63 is also incremented 46 j for the customer list 62 to Customer ID “B” and the process repeats until all entries in the master list 62 have been used.
[0045] The merging process 46 scans down the lists by incrementing the cursors when merging 46 finds intersections of age and income. The intersections are used to populate the two-dimensional array 80 ( FIG. 6 ). The single-pass scanning process can be visualized as popping each entry off of the list, analogous to incrementing pointers and popping entries off of stacks. In the lists 62 , 64 a - 64 d and 66 a - 66 d, the entries are guaranteed to be in order because the entries are sorted. The lists are sorted alphabetically if the values are text strings or numerically if they are numbers. Any sort order can be used as long as the sort criteria are consistent across the master list and all sub-lists.
[0046] The process 46 calculates the values for each cell in the structure 80 , which could be simple counts. The process 46 scans all the lists in one pass. The process goes down the master list 62 of CIDs and looks for a value of that CID in sub-lists 64 a - 64 d and 66 a - 66 d. When the process finds the value of the CID for all dimensions of data in the sub-lists 64 a - 64 d and 66 a - 66 d , the process performs the required calculations (e.g., adds the occurrence to the value already in the cell for computing simple counts) in the cross-table and increments only those cursors of cursors 67 a - 67 d and 69 a - 69 d of the sub-lists where the values were found. Thus, the initial sorting of the results of the query allows the cross-tabulation structure to be constructed from a single linear pass through the sub-lists 64 a - 64 d and 66 a - 66 d.
[0047] If the sub-lists of a dimension are mutually exclusive (i.e., the sub-lists do not have common members and the queries used to from the sub-lists had disjoint boundaries), once the process 46 finds the CID in a sub-list of a dimension, the process 46 no longer needs to search through the other sub-lists for that dimension, as is indicated in 46 f of FIG. 7 . If the sub-lists of a dimension are not mutually exclusive, (i.e., the sub-lists may have common members and the queries used to form the sub-lists had overlapping boundaries), then once the process finds the CID in one sub-list of a dimension, the process still scans the remaining sub-lists of that dimension for additional occurrences of that value of CID.
[0048] The process 40 allows the user to specify the dimensions and the raw SQL statements, thus allowing the user to specify 2 dimensions, 3 dimensions, and so forth. The process 40 executes the sets of queries for each specified dimension only once, while the construction of each structure is accomplished by a single-pass matching/merging process of the sorted ID lists.
[0049] The process 40 performs pre-aggregation of data for fast display/drilling by computing a structure quickly after some initial sorting operations. The process 40 can work over multiple dimensions of data (e.g., age, income), where it is need to aggregate data over multiple dimensions (2 or more) for analysis avoiding an exponential growth problem situation. The algorithm performs a very efficient 1-pass through the data.
[0050] The process 40 allows the user to specify the dimensions in a query statement, thus allowing the user to specify 2 dimensions, 3 dimensions, and so forth. The process 40 executes sets of queries for each specified dimension only once, while constructing a structure by performing matching/merging processes on sorted ID lists, e.g., 64 a - 64 d and 66 a - 66 d. The process 40 performs pre-aggregation of data for fast display/drill-down by computing structure 80 quickly. The process can work over multiple dimensions of data, where it is needed to aggregate data over multiple dimensions for analysis while avoiding an exponential growth situation. The algorithm performs a very efficient 1-pass through the data.
[0051] The process 40 provides a number of performance improvements over competing processes. For instance, speed of calculations is based on sum of the number of bins over all dimensions, though if multiple hierarchical levels of a dimension can be rolled up from lower levels, only queries for the lowest level of granularity need to be executed, further increasing the computational efficiency. For a single-dimension query, the computation is of order (n log n), where n is the number of rows of data being processed, assuming that the data is not sorted. For calculating multiple dimensions, the calculation is of the order of n log n times m, where m is the number of levels across all dimensions (or the number at the most granular levels across all dimensions if the hierarchy can be rolled up from lower levels). If the data is returned from a database with the fields already sorted, the calculation complexity is of the order (n×m). This approach can be 10 to 100 times faster than competing approaches which have calculations on the order of n*the number of complex queries=f (number of dimensions and levels).
[0052] Furthermore, the process 40 simplifies the queries that are required to be executed by the database 32 . Two queries of the form “Field1=X” and “Field2=Y” are computationally more efficient to execute than a single query of the form “Field1=X AND Field2=Y”. Not only does the cross-tabulation process 40 reduce the number of queries required from a geometric progression to a linear one, it also reduces the complexity of the queries to be executed. This adds to the performance advantage of this approach.
[0053] The process 40 can be used with more than two dimensions, e.g., adding a 3rd dimension (age, income, geography) to the example, requires 12 queries (assuming each dimension has 4 sublevels) to handle 64 total cells. The number of required queries to execute the cross-tabulation 40 increases linearly (n+m+ . . . +x), where n, m, . . . , x represent the number of sublevels in each dimension, while analysis increases geometrically (n m* . . . *x).
[0054] Referring to FIG. 8 , another example of a cross-tabulation structure 90 here having three dimensions is shown. In FIG. 8 , the third dimension (e.g., territory) is added to the query to produce data from the database. The number of cells thus increases by a factor of the number of levels of “territory.” The table in FIG. 8 has age, income, and territory dimensions (each with 4 sublevels, and hence 64 cells in the structure 90 ). The territory dimensions are denoted as W, X, Y and Z. The number of queries that the process generates is 3×4=12 plus 1 query for the master list for a total of 13 queries. With the 13 queries, the process can handle 64 cells of accumulation (4*4*4).
[0055] Computing efficiency for an increased number of dimensions is related to the number of levels in each dimension. For example, assume that along the age dimension is a top Level “All”, sublevels “Young|Middle|Old”, and each of the sublevels are broken down into further sub-sublevels “16-21, 22-25, 26-30”, “31-35, 36-40, 41-50”, and “51-60, 61-70, 71+.” Thus, there is one level ALL, there are sublevels YOUNG, MID and OLD, and underneath the sublevels there are 9 additional sub-sublevels of numerical age groupings. In this situation, if a user wanted to completely compute the cross-product through all of the levels and be able to determine how many people are young what income at specified level, there would be a larger number of cells in the cube.
[0056] When upper levels can be easily computed from lower levels (i.e., the boundaries of lower levels roll up cleaning into upper levels), the number of queries that the process would issue would be equal to the sum of numbers of the lowest level per dimension. So the number of computations is equal to the sum across all dimensions over the number of bins in the lowest dimension.
[0057] If the bins overlap then the number of queries is equal to not just number of bins in the lowest level, but the number of bins overall. In this case the number of queries would be 9 queries for the sub-sublevels, plus 3 queries for the sublevels for a total of 12 queries to generate the sublists for the AGE dimension. If the problem also now has 12 income dimensions, there are 144 cross intersections, but the process only has to issue 25 queries (12 for each dimension plus one query to generate the master list) to get the 144 cross-intersections. The more complex the levels are in a single dimension (both in depth as well as in the number of bins/granularity) and the larger are the number of dimensions, the higher the number of computations that are required.
[0058] Another feature of the technique is that the analysis can be easily performed over groups of cells. Assume that there are 50 groups of cells (which can be disjoint or overlapping) for which age and income computations are desired. Issuing queries would provide 50 lists of Ids for which 50 different cross tabulations would be computed. Thus, if there are 50 groups of cells for an age/income analysis, the process would combine (e.g., “OR”) all of the IDs into a single long master list, which is sorted and deduped (duplicates removed). Thereafter the process is similar to working on a single cell, except that indexes are also kept in each of the original 50 ID lists to determine which of the 50 cross-tabs are incremented as IDs are processed from the master list. The process produces one cross-tabulation table (n×n structure) to hold the count for each of the groups. The process scans down the master list, each of the 50 segment lists, and the dimension sub-lists in the single pass and aggregates values to the appropriate cross-tabulation cells.
[0059] Other embodiments are possible for the computation of multiple segments for the same dimension. For instance, lists for each bin in each dimension can be periodically pre-computed for the entire population. Once these lists are generated, the process can use the arbitrary segments of population and compare them against the segmented list of customer IDs to find intersections. That is, no matter how many segments there are, the process does not need to issue any queries to get the lists for the dimension bins. This allows the process to generate cubes very fast for any segment without issuing any query for counts (and only issuing one query to get the fields that are needed to accumulate or process the cells of the cubes).
[0060] The process can be expanded to perform other functions on the data represented in the database. Thus, in addition to summing, the process can provide average counts, minimum counts, maximum counts, a standard deviation of another variable (e.g., sum of account balances, averaged tenure), and so forth. The additional variable(s) are brought back as part of the master list and are referenced for the required computations (rather than bringing the variable back with each sub-list). The process can also compute non-intersection of cells.
[0061] 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. For example, age, income and territory are examples of 3 attributes or customer characteristic. Other characteristics could be used as dimensions for instance, recency of purchase, frequency of purchase and an aggregate of amount of purchases so called RFM characteristics. Accordingly, other embodiments are within the scope of the following claims.
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Techniques for producing a cross tabulation are described. The techniques involve issuing a plurality of queries to a database. The queries are for each of at least one sublevel of data for each of at least one dimension of data associated with records in the database. The queries provide sublists of sorted identifiers for each one of the queries. The technique determines occurrences of intersections of levels of one dimension with levels of another dimension of the data associated with records in the database by traversing the sublists to detect intersections of the dimensions.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 61/896,381 filed on Oct. 28, 2013. The above identified patent application is herein incorporated by reference in its entirety to provide continuity of disclosure.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to footwear covers. More specifically, it relates to a decorative cover for boots, having optional adornments and multiple styling configurations. The cover is ideally suited for use with boots that have aesthetic damage, or are out of style.
[0004] Fashion trends change with every passing season. So to does the style of footwear that is en vogue. One season, a knee high colored patent leather boots may be “all the rage”, while the next season brings with it gladiator style sandals with wedge heels. The rapidity with which trends change makes them difficult to follow and even harder to afford. Acquiring the latest and greatest footwear each season can cost hundreds if not thousands of dollars each season. Many a pocketbook, and a relationship, has been strained over the desire to have fashionable footwear at all times.
[0005] In some seasons, the difference between fashion styles is subtle. A pair of boots that were fashionable last season may be essentially the same as a pair of boots that are fashionable this season, except that they lack fur trim. For many people it is difficult to justify the purchase of the newer pair of shoes if last season's fashion is already owned. People who regularly purchase new shoes to keep up with changing fashions may find themselves owning several pairs of nearly identical shoes.
[0006] A shoe modification system is needed that enables users to update the appearance of footwear. The present invention solves this problem by providing a means for adding adornment to a pair of shoes. In this way, it helps users keep up with the latest footwear fashion trends while saving money.
[0007] 2. Description of the Prior Art
[0008] Devices have been disclosed in the prior art that relate to footwear coverings. These include devices that have been patented and published in patent application publications. These devices generally relate to protective coverings for footwear. The following is a list of devices deemed most relevant to the present disclosure, which are herein described for the purposes of highlighting and differentiating the unique aspects of the present invention, and further highlighting the drawbacks existing in the prior art.
[0009] Coh, U.S. Pat. No. 5,501,022 discloses a tubular boot covering. The boot covering is a tube of material that slides down over the calf portion of the boot, covering the boot from top to ankle. Although Cohn discloses the use of several styles of tube and a variety of materials, it does not disclose additional panels, and removable elements. In this way the present invention is superior to the Cohn device because it provides users with a high degree of customization. A similar device is disclosed by Tweedie, U.S. Pat. No. 1,153,977. The Tweedie device is another boot cover and features lace façade on the front to provide the appearance of being a part of the boot. A portion of the lower edge of the boot cover may secure around the boot sole to keep the device in position during use. The Tweedie invention suffers from the same drawbacks as the Cohn device.
[0010] A variation on the tubular boot covering is disclosed in Datson, U.S. Pat. No. 4,856,207. The boot covering is a protective device that reduces damage to boots during use. The device is tubular with a series of button snaps aligned in a vertical column. The snaps enable easy application and removal of the device. Datson does not disclose the use of any trim panels, additional straps, or hanging adornments.
[0011] Other patents disclose single boot adornment elements. Castle, U.S. patent application publication no. 2012/0174442 discloses a clip for the upper edges f calf length boots. The clip is shaped like a bangle style bracelet. It is a solid circlet with a break in the loop at one portion. The loop can be pried apart at the break to enable insertion of the boot upper edge. The clip is then secured onto the upper edge of the boot, forming a decorative edge trim once in place. Paraszczak, U.S. patent application publication no. 8353117 teaches another edge trim decoration for a boot. The device is a strap, with a monogram plate that slides over the strap. The monogram plate can be switched out for different letters and symbols so that users can customize the displayed letters. Once the desired monogram plate(s) is affixed, the strap is buckle around the top of a boot. Unlike the present invention, these devices do not cover any portion of the calf of the boot, nor does it offer decorative elements around the ankle region.
[0012] These prior art devices have several known drawbacks. None of these devices teaches a plurality of elements that can be assembled in a customizable configuration to form a decorative and protective boot cover. The present invention incldes a number of structural elements that are combined to form a boot cover with the appearance desired by the user. It substantially diverges in design elements from the prior art and consequently it is clear that there is a need in the art for an improvement to existing footwear covering devices. In this regard the instant invention substantially fulfills these needs.
SUMMARY OF THE INVENTION
[0013] In view of the foregoing disadvantages inherent in the known types of footwear modification devices now present in the prior art, the present invention provides a new customizable foot cover wherein the same can be utilized for providing convenience for the user when updating the look of shoes and boots
[0014] It is therefore an object of the present invention to provide a new and improved customizable footwear covering device that has all of the advantages of the prior art and none of the disadvantages.
[0015] It is another object of the present invention to provide a footwear cover that can be adorned with a selection of optional elements.
[0016] Another object of the present invention is to provide a foot cover that removably secures to a pair of boots, covering blemishes, scratches, and imperfections that would otherwise deter the user from wearing the shoes.
[0017] Yet another object of the present invention is to provide the user with a cheap and efficient way to update the look of a pair of shoes.
[0018] Still another object of the present invention is to provide footwear covering that can protect the exterior of a pair of shoes or boots.
[0019] A further object of the present invention is to provide a modifiable and customizable footwear covering that enables users to express personal creativity in designing the look of their shoes.
[0020] A Still further object of the present invention is to provide footwear covering that may be readily fabricated from materials that permit relative economy and are commensurate with durability.
[0021] Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0022] Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.
[0023] FIG. 1 shows an overhead view of an exemplary implementation of the unassembled parts of the modifiable footwear covering device.
[0024] FIG. 2 shows a perspective view of an exemplary configuration of the footwear covering decorative elements, in use. The footwear covering is wrapped around the calf portion of a knee-high boot.
[0025] FIG. 3 shows a perspective view of the modifiable footwear covering being applied to the calf region of a boot.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the modifiable footwear covering. For the purposes of presenting a brief and clear description of the present invention, the preferred embodiment will be discussed as used for customizing the appearance of a shoe or boot. The figures are intended for representative purposes only and should not be considered to be limiting in any respect.
[0027] Referring now to FIG. 1 , there is shown an exemplary implementation of the footwear covering device with its individual elements separated. The footwear covering 100 has a base panel 110 , trim panel 120 , adornment straps 130 , and hanging adornments 150 , 151 . These components may be arranged in a variety of combinations to create unique designs, as well as to add or remove functionality. By way of example, the addition of fur trim to the footwear covering may increase insulation of a user's upper calf, an advantageous feature during cold weather. Users can easily add or remove design elements from the base panel. As styles and trends change, a user can add new fashion elements and remove those that have become outdated.
[0028] The base panel 110 is configured to wrap around the calf, ankle, and upper foot region of the wearer, whereby the base panel comprises side edges that fasten together. A zip fastener line of connection secures the side edges to one another, forming a substantially cylindrical shape for the wearer's leg to reside. The upper edge 111 of the base panel further comprises a fastener 111 thereon, which is used to secure the trim panel 120 thereto. The fastener 111 preferably comprises a strip of hook and loop fastening, however alternate fasteners are contemplated.
[0029] One example of the assembled device in use is shown in FIG. 2 . The footwear covering 100 is removably secured over a footwear article. A trim panel 120 of faux fur is removably secured to the upper edge of the base panel 110 . This creates the appearance of a fur trim extending from the top of the boot. Trim panels 120 are attached via the upper fastener (e.g. hook and loop fasteners, buttons, snaps, or the like), and disposed along an upper edge of the base panel 110 , and on the inner or outer face thereof. Complimentary fasteners along the trim panel secure the trim panel 120 to the base panel 110 . Each hanging adornment has an attachment loop 151 disposed at one end and a distal end 130 . The loop is secured by the trim panel 120 , which is disposed through the attachment loop 151 of the hanging adornment. In this way, a hanging adornment can be incorporated into the footwear covering. In other embodiments, the hanging adornment may snap or otherwise fastener directly to the base panel 110 .
[0030] An adornment strap 130 may also be affixed around the lower edge of the base panel 110 of the device 100 . The adornment straps have an adjustable length, whereby a buckle is disposed at one end of the strap 130 . The strap 130 is buckled around the ankle area, to create an aesthetically pleasing mask for the lower edge of the footwear covering. In some embodiments, the lower edge of the base panel may have snaps, hook and loop fasteners, or other fastening means that mate with corresponding fasteners disposed along all or part of the rear face of the adornment straps. Thus, the adornment strap 130 can be secured to a portion of the base panel 110 directly. This embodiment reduces shifting of the adornment straps 130 when in use, and provides a better mask for the base panel lower edge.
[0031] Assembled, the footwear covering device provides the appearance of being a part of the underlying footwear 200 . In the example illustrated in FIG. 3 , the Base panel 110 covers the upper portion of a knee-high boot, including the area from the upper edge of the boot down to the user's ankle. The side edges of the base panel zip fasten together, encircling the upper portion of the boot. Once positioned, the footwear covering provides an aesthetically pleasing protective covering for the footwear, hiding any visible damage to the boot and reducing the likelihood that further damage will occur.
[0032] In some embodiments, the base panel 110 is a rectangular panel of material bounded by an upper edge, a lower edge, and opposing side edges. Dimensions of the base panel will vary depending upon the type of shoe the foot cover will be used to cover. Taller shoes like boots will require larger base panels than ankle booties. A zipper, hook and eyelet closure, or similar closure means is disposed along the two side edges, each side edge having half of a mating portion of the closure means. Depicted in the figures are vertical zipper halves disposed along the length of edge side edge, the zipper halves combining in use to form a line of securement. The interior surface of the base panel may be lined or unlined depending upon the need to protect the underlying shoe from the base panel. Base panels constructed of abrasive fabrics may need to be lined to protect the underling boot.
[0033] Trim panels 120 are rectangular panels having a width equal to or greater than that of the base panel 110 . Vertical height of the trim panels is significantly less than that of the base panel, as the trim panels are intended to cover only a portion near the upper edge of the base panel when in use. Each trim panel may be constructed of, or covered in a different material. One trim panel may be made of a faux fur fabric, while another is a panel of material covered in sequins. Still another panel may be plain, and made of the same material as the base panel, but in a contrasting color or pattern. The rear surface of each trim panel has a strip of hook and loop fastener or other fastening means disposed thereon, This hook and loop fastener mates with hook and loop fastener disposed along a portion of the upper edge of the base panel. The base panel hook and loop fastener may be disposed along the front face, rear face, or both. In this manner, trim panels can easily be applied and removed, giving the base panel a different appearance with each application.
[0034] Adornment straps 130 are straps with buckles or snaps disposed at one end. Each strap is sized to wrap around the boot cover when in use. A variety of different types of decorations may adorn the straps. Conchos, gemstones, glitter, embossing, and other forms of decoration may be applied to the adornment straps. When these straps are fastened around the footwear covering, the overall design of the device is changed. Users may have a number of adornment straps and may switch them out for different occasions. Adornment hangers 150 are short strips of material with a securable loop at one end and one or more adornments disposed thereon. The loop is secured by the trim panels 120 or are fastened directly to the base panel, such that the adornment hanger hangs down the side of the footwear covering in use. Tassels, conchos, chain links, and the like may be used as adornment hangers, to create an attractive, dangling feature.
[0035] The footwear covering device may be made form a variety of materials. Because some users may desire for the footwear covering to look like it is part of the underlying shoe, the covering may be offered in many different shades and finishes of leather. In some embodiments, the support and adornment straps are constructed of the same material as the base panel. In other embodiments, the support and adornment straps are made of contrasting leather.
[0036] The present invention is a footwear covering that encircles the wear's ankle and calf regions when in use. The appearance of the footwear covering is customizable via trim panels, adornment straps, and adornment hangers. Users can modify the footwear covering as desired and place it over damaged boots to cover up deep scratches, water damage or the like. The footwear covering can also be used to update the look of older footwear. By way of illustration, boots that are several years old but in good condition may be covered with the footwear covering and adorned with rhinestones, or other fashionable embellishments.
[0037] It is therefore submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, 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.
[0038] 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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Provided is footwear covering device that covers the calf and ankle region of a piece of footwear. The device has a base panel that is modifiable with trim panels, adornment straps, and adornment hangers. Trim panels may have glitter, velvet, faux fur or other material suitable for adding accent to the upper edge of a boot. The trim is removably secured to the top of the footwear covering and thus appears as edge trim for the underlying footwear when in use. Adornment straps and hangers having decorative embellishments are wrapped around the footwear covering, or allowed to hang downward form an upper edge. Thus, each user can customize the overall appearance of the footwear covering to his or her liking. The covering can be placed over old or damaged footwear to provide a fresh new appearance that protects the underlying footwear from damage.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
BACKGROUND OF THE INVENTION
[0002] This invention relates to opening frameless windows, used in recreational vehicles, trailers, trucks, boats, and the like, in a position basically parallel orientation to the window frame. Prior art is limited to methods for opening windows which are attached to the window frame by some form of a hinge.
[0003] The Field of Search is contained within U.S. Patent Class 49, Movable or Removable Closures, and more specifically the following subclasses: 49/219, 49/221, 49/212, 49/127, 49/128, 49/129, 49/130, 49/209, 49/210, 49/248, 49/193, and 49/252.
[0004] The following references are cited:
[0000] U.S. Pat. No. 3,841,024, October 1974, Cheng
U.S. Pat. No. 4,042,004, August 1977, Kwan
U.S. Pat. No. 4,551,945, November 1985, von Resch
BRIEF SUMMARY OF THE INVENTION
[0005] This invention relates to fully opening frameless windows, used in recreational vehicles, trailers, trucks, boats, and the like, which will hereinafter be referred to as a vehicle. Current frameless windows have the disadvantage that they cannot be fully opened. They are designed to only partially open, pivoting on a hinge along one edge of the glass pane which is attached directly to a window frame attached to the vehicle, as illustrated in von Resch, U.S. Pat. No. 4,551,945. Current frameless window designs allow for only minimal airflow through the window frame. The current designs for opening frameless windows could be modified to allow the window pane to swing open more fully; however, this method of opening frameless windows results in the window pane being rotated toward a perpendicular position compared to the window frame, causing the window pane to extend far outside the plane defined by the window frame.
[0006] This invention is directed to hardware for a frameless window so that the window pane can be displaced to allow for full air flow through the window frame, with the window pane being in a parallel position to the window frame. A window pane is translated from a first, closed position into a second, open position, and then slid into a third, open position with the movement being effected by swing arms, control arms, sliding mechanisms, handles, and latching mechanisms. In each position, this invention holds the window pane securely so that an external force, such as wind or manual exertion, against the glass pane can move it to another position. This invention can be used with a frameless window assembly with a single window pane or with a frameless window assembly composed of a plurality of window panes which may be fixed or movable. If this invention is applied to a single window pane, all or part of the window pane may extend outside the window frame over the vehicle wall when open to fully open the air passage through the window frame. If this invention is applied to a frameless window assembly composed of a plurality of panes, the window panes to which the invention is applied may be opened either over the vehicle wall or over other panes in the window assembly. This invention also allows for restricted air flow through the window frame by not fully opening the window pane. This invention applies to a flat or curved glass pane, as well as a flat or curved vehicle wall. Most window panes are composed of glass, and will be hereinafter referred to as glass panes to minimize potential confusion with reference to window frames, although the window pane may be composed of other materials such as polycarbonate.
[0007] In the preferred embodiment of this invention, two sets of hardware are used on each glass pane. The sets of hardware function symmetrically, providing for parallel sliding mechanisms which allow the glass pane to move in a lateral direction while being supported on two sides. Most applications of this invention will be designed for horizontal sliding of the glass pane, which would mean that the hardware would typically be located on the top and bottom of the window frame. In alternative embodiments of this invention, the glass pane will move in any direction along the line of the parallel sliding mechanisms. In such embodiments, it may be advisable to install counter weights to facilitate lifting or supporting of the glass pane.
[0008] In the preferred embodiment of this invention, sliding mechanisms are attached to the glass pane either mechanically or with adhesive. Sliding mechanisms are telescopic in nature and can be composed of two or more parts, allowing various distances of extension when the sliding mechanisms are extended from their retracted state. One part of the sliding mechanism is attached to the glass pane, while another part of the sliding mechanism is attached to the swing arms and control arms which are attached to the window frame. This attachment method secures this part of the sliding mechanism so that it may be moved only between the first and the second positions. The glass pane can then be slid from the second position to the third position as the telescopic sliding mechanisms are extended.
[0009] One advantage of this invention is its simple and inexpensive method of holding the glass pane securely. In the preferred embodiment of this invention, swing arms must be long enough to allow for the sliding mechanisms and glass pane to be translated from the first to second positions with the swing arms being rotated toward 90 degrees from the plane of the window frame. The swing arms are used to support the weight of the glass pan and sliding mechanisms from the window frame, and the translation distance must be sufficient to allow the sliding mechanism and glass pane to extend outside the window frame and over the exterior vehicle wall or over an adjacent glass pane. As the swing arms pivot about their attachment points to the window frame, the sliding mechanisms and glass pane move in both a parallel translation and lateral direction. It is necessary, therefore, that the sliding mechanisms be placed sufficiently far from the window frame to allow for lateral movement of the sliding mechanisms without interference from the window frame. The translation distance can be calculated by multiplying the length of the swing arm by the trigonometric value of sin THETA, where THETA is the angle between the window frame and the swing arm. THETA must be less than 90 degrees, and the longer the swing arm, the greater the translation distance when THETA is small. The translation distance from the first or closed position to the second position is calculated by the length of the swing arm times the value of sin THETA second position minus sin THETA first or closed position. The translation distance must exceed the distance needed so that the sliding mechanism can extend into the third position without interference from the vehicle wall or other glass pane. The lateral displacement when moving from the first or closed position to the second position is calculated by the length of the swing arm times the value of cos THETA first minus cos THETA second position. The sliding mechanism must be placed far enough away from the window frame so that it may be moved into the second position without interference from the window frame. The lateral displacement is smaller when THETAs are smaller. In an alternative embodiment of this invention, telescopic arms could be used in place of the swing arms. In such an alternative embodiment of this invention, the glass pane would not experience a lateral displacement when moving from the first or closed position to the second position.
[0010] If the dimension of the window frame is small, the swing arms can be curved rather than straight to effect the necessary transition from first to second position. Furthermore, the control arms may overlap the swing arms.
[0011] One advantage of this invention is its simple and inexpensive mechanism for holding the sliding mechanism securely in second position. In the preferred embodiment of this invention, one or two control arms attach the window frame to a control arm sliding rail which is attached to the part of the sliding mechanism that remains in the second position. The control arms are manually manipulated to extend or retract the glass pane between the first or closed position and the second position. The control arm manipulation mechanism causes the control arms to extend and retract the glass pane. A control arm mechanism with two control arms would function with a scissor-type movement. Movement of the control arms is similar in motion to the swing arms. In the preferred embodiment of this invention, a stopping block is attached within the control arm rail to specify the distance of translation of the sliding mechanisms from the first or closed position to the second position. Alternatively, other methods of stopping the control arm extension, such as insertion of a pin or a deformation in the control arm sliding rail, could similarly control and determine the distance of translation of the sliding mechanisms from the first or closed position to the second position. Because the sliding mechanisms and glass pane experience lateral displacement during the movement from the first or closed position to second position, the location of the control arm rail on the sliding mechanism, as well as the stopping block within the control arm rail, must be considered to allow for proper functioning of the control arms during the lateral displacement of the glass pane. The control arm rail must also move from the first to second position without interference from the window frame. In the preferred embodiment of this invention, the control arm manipulation mechanism is operated manually to move the glass pane from first or closed position to second position, and then back to first or closed position. In an alternative embodiment of this invention, a mechanism such as a control cable or push rod which translates the glass pane from the first to second position could be used instead of control arms. In another alternative embodiment of this invention, a locking arm or mechanism could be attached to a swing arm. In another alternative embodiment of this invention, an electronic assembly could be used to manipulate the control arms. In alternative embodiments of this invention, electronic or mechanical gearing, cables, or other means could be used to move the glass pane from second and third positions. The preferred embodiment presented herein provides an inexpensive means of opening and closing the glass pane.
[0012] One advantage of this invention is the capability to hold the glass securely in not only the first or closed position, but also both second and third positions. In the preferred embodiment of this invention, a handle is attached to the part of the sliding mechanism which is attached to the glass pane on at least one of the two parallel sliding mechanisms. The handle is long enough to be accessible from inside the vehicle in which the window frame is installed when the glass pane is translated from first to second position. A third position latching mechanism secures the handle when the glass pane is in the second position. In the preferred embodiment of this invention, because of the lateral translation from going between the first and second positions, one side of the handle is contoured so that the edge of the handle remains close to the edge of the third position latching mechanism when moving between first and second positions. This allows the glass pane to remain secure during movement between first and second positions, allowing the glass pane to be only partially opened if limited airflow through the window frame is desired. The glass pane can remain in the second position and allow for modest air flow, but not the full air flow available when the window is opened in the third position. In the preferred embodiment of this invention, in order for the glass pane to be slid from the second to the third position, the third position latching mechanism must be manually opened to allow the handle to be slid from the second position to the third position. When the handle is slid to the third position, it is held in place by a third position latching mechanism. With the glass pane in the third position, the window is fully opened, allowing the free flow of air through the window frame. In the preferred embodiment of this invention, the third position latch must be manually opened to allow the handle to slide back to the third position latching mechanism. In an alternative embodiment of the invention, the sliding mechanism may contain features which hold the glass pane in the second and third positions. However, exterior forces from outside the vehicle can unintentionally and more easily move the glass pane from its position.
[0013] Another advantage of this invention is the control of movement from first or closed position to second position, and then from second position to third position. Similar control is in place for the reverse sequence of movements from third position to second position, and then from second position to first or closed position. The first step in opening the frameless window must be manual manipulation of the control arms to effect the translation of the glass pane from first or closed position to second position. In other words, it is not possible to make a lateral translation directly from first or closed position to third position since the glass pane is held securely to the window frame while in first or closed position. Once the glass pane is in the second position, it can then be moved to either the first or third position. In order to prevent an attempt to move the glass pane from the third position directly to the first or closed position by manually manipulating the control arms, which could damage the exterior vehicle wall, the handle is notched so that the third position latching mechanism prevents the translation of the glass pane to the first or closed position. An attempt to retract the control arms while the glass pane is in the third positions fails. The window will thus be moved to the second position before it is moved back to the first or closed position.
[0014] With the exception of an opening to allow the handle to slide from second to third position, the preferred embodiment of this invention provides for screens to cover the entire window frame, preventing passage of insects or debris into the vehicle. Screen assemblies cover the hardware which is used to move the glass pane between first and second positions. The remaining area of the window frame is covered by a screen. Because the handle is used to slide the glass pane from second to third position, in the preferred embodiment of this invention, the edges of the screens between which the handle passes have brush strips which allow the handle to slide between them, while preventing passage of insects or debris through the brush strips. In alternative embodiments of this invention, other materials such as rubber or plastic extrusions could be used to allow handle movement and prevent passage of insects or debris through the handle sliding area.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0015] FIG. 1 is an enlarged vertical sectional view of the invention in the first or closed position taken along line II-II of FIG. 4 .
[0016] FIG. 2 is an enlarged vertical sectional view of the invention in the second position taken along the along line II-II of FIG. 4 .
[0017] FIG. 3 is an elevation view of a glass pane opened outside a window frame in the third position provided with the hardware embodying the present invention, attached to the top and bottom of the window frame, and top and bottom of the glass pane, to allow the window to reside outside the window frame.
[0018] FIG. 4 is an elevation of the opposite side of FIG. 3 with the glass pane in the first or closed position as would be visible by a person inside a vehicle in which the present invention is installed.
[0019] FIG. 5 is a horizontal sectional view of the invention in the first or closed position taken along the lines III-III of FIG. 4 .
[0020] FIG. 6 is a horizontal sectional view of the invention in the second position, based on the horizontal sectional view of FIG. 5 .
[0021] FIG. 7 is a horizontal sectional view of the invention in the third position, based on the horizontal sectional view of FIG. 5 .
[0022] FIG. 8 is an elevation view of the handle 65 .
[0023] FIG. 9 is an elevation view of the controller arm assembly in the first or closed position.
[0024] FIG. 10 is an elevation view of the controller arm assembly in the second and third positions.
[0025] FIG. 11 is a top view of the swing arm assembly.
[0026] FIG. 12 is an elevation view of the swing arm assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0027] In FIG. 1 , in the first or closed position, glass pane 1 is located outside of exterior window frame 2 . Glass pane 1 is generally constructed of glass, but may be constructed of other materials including polycarbonate. Exterior window frame 2 is commonly constructed of aluminum, but may be constructed of other materials including vinyl and plastic. Exterior window frame 2 is inserted into the vehicle wall 5 . Interior window frame 3 is also inserted into the vehicle wall 5 . Interior window frame 3 is generally composed of the same material as exterior window frame 2 , but may be composed of another material. Vehicle wall 5 is typically composed of wood, but may be composed of other materials. The exterior of vehicle wall 5 is typically covered by exterior vehicle wall surface 6 is typically composed of fiberglass or aluminum siding, but may be composed of other materials. The interior of vehicle wall 5 is covered by interior vehicle wall surface 7 , which is typically composed of wood paneling, but could be composed of other materials. Exterior window frame 2 and interior window frame 3 are attached together with screws 4 , but could be attached together using other attachment technologies such as rivets.
[0028] When exterior window frame 2 is installed into vehicle wall 5 , putty 8 is placed between the exterior window frame 2 and the exterior vehicle wall surface 6 to provide a seal which prevents intrusion of water, insects, wind and other items from passing through the gap between exterior window frame 2 and the exterior vehicle wall surface 6 . The material used for putty 8 may be substituted by other materials including silicone or rubber.
[0029] In the first or closed position, glass pane 1 is pressed against window seal 9 . Window seal 9 provides a seal between glass pane 1 and the exterior window frame 2 to prevent water, insects, wind, and other items from passing through the gap between glass pane 1 and exterior window frame 2 .
[0030] Lower perimeter controller frame 10 is attached to exterior window frame 2 using various rivets 11 , 60 . Different types of attachment technologies may be used, such as welding or screws. Lower perimeter controller frame 10 is made of stainless steel or another strong material. In cases where exterior window frame 2 is composed of a highly durable material, it is possible to eliminate lower perimeter controller frame 10 . However, in cases where exterior window frame 10 is composed of a softer material, such as plastic, perimeter controller frame 10 is necessary.
[0031] Swing arm 12 is attached to lower perimeter controller frame 10 by swing arm rotation rivet 13 . FIG. 11 shows a top view of swing arm 12 and swing arm rotation rivet 13 , and FIG. 12 shows the corresponding side view. Swing arm rotation rivet 13 is the single point of attachment of swing arm 12 to lower perimeter controller frame 10 . Swing arm rotational rivet 13 provides a standoff distance between swing arm 12 and lower perimeter controller frame 10 . A swing arm standoff is attached to swing arm 12 on each side of swing arm rotation rivet 13 . Exterior swing arm standoff 15 and interior swing arm standoff 16 are dimensioned so that the distance between swing arm 12 and lower perimeter controller frame 10 is the same as the distance defined by the standoff distance of swing arm rotational rivet 13 . With the swing arm 12 being parallel to lower perimeter controller frame 10 because of the equal standoff distances of exterior swing arm standoff 15 , interior swing arm standoff 16 , and swing arm rotation rivet 13 , swing arm 12 is able to rotate only side to side in a parallel plane to lower perimeter controller frame 10 around swing arm rotation rivet 13 . Swing arm 12 is not able to significantly move up and down in a perpendicular movement to lower perimeter controller frame 10 . FIG. 2 shows swing arm 12 in a rotated position.
[0032] A sliding mechanism composed of an exterior sliding mechanism 19 , center sliding mechanism 18 , and interior sliding mechanism 17 is attached to glass pane 1 . The sliding mechanism is similar to that used as drawer slides and can be composed of at least two pieces. In this invention, the sliding mechanism is defined with three pieces. The sliding mechanism construction functions with the use of ball bearings. Exterior ball bearings 21 allow a sliding movement between exterior sliding mechanism 19 and center sliding mechanism 18 , and interior ball bearings 20 allow a sliding movement between center sliding mechanism 18 and interior sliding mechanism 17 . Exterior sliding mechanism 19 is attached directly to glass pane 1 through adhesive 22 . A common brand of adhesive 22 for such an invention is manufactured by Sika. Exterior sliding mechanism 19 could also be attached to glass pane 1 by other means such as bolts.
[0033] Interior sliding mechanism 17 is attached to sliding mechanism bracket 23 through the use of rivets 61 . Other means of attachment such as adhesive or bolts could be used. Sliding mechanism bracket 23 is attached to swing arm 12 through slider bracket rotation rivet 14 . A top view of sliding mechanism bracket rotation rivet 14 is illustrated in FIG. 11 , with a side view being illustrated in FIG. 12 .
[0034] In this invention, at least two slide arms 12 are attached to sliding mechanism bracket 23 . FIG. 6 and FIG. 7 show two slide arms 12 in a rotated position. One of the two slide arms 12 is shown in FIG. 5 in a non-rotated position; the other is covered by sliding mechanism bracket 23 . When sliding mechanism bracket 23 is in the rotated position, as shown in FIG. 6 and FIG. 7 , sliding mechanism bracket 23 has been moved laterally in the direction of rotation. Rivets 61 is not shown as a cross section in FIG. 1 when in the non-rotated position, as it is off the cross section line, but moves into the cross section line in the rotated position as illustrated in FIG. 2 . FIG. 6 illustrates that rotation of the slide arms 12 causes glass pane 1 to be extended outside exterior window frame 2 in a position parallel to exterior window frame 2 .
[0035] Referring to FIG. 4 , controller arm housing 30 is attached to housing attachment plate 32 with housing screws 67 . Housing screws 67 are shown in FIG. 4 , partially covered by control arm handle 33 . In the current invention, housing attachment plate 32 is attached to exterior window frame 2 with rivets 29 . Other attachment technologies such as screws could be used instead of rivets 29 . In other embodiments of this invention, controller arm housing 30 could be attached directly to exterior window frame 2 or interior window frame 3 . Use of the housing attachment plate 32 allows for less product cost as the flange the exterior window frame 2 or interior window frame 3 to which attachment plate 32 would be attached, would need to be larger than illustrated in the current embodiment. Controller arm 25 is attached to controller arm housing 30 and can be extended or retracted by turning the controller arm screw 31 which has gears to cause movement of controller arm 25 . Controller arm screw 31 is turned by clockwise or counter-clockwise movement of control arm handle 33 to which it is connected. In the current embodiment of this invention, two controller arms 25 are attached to controller arm housing 30 . This is a common scissor-like design. Single controller arms 25 can also be used. FIG. 5 and FIG. 9 show views of controller arms 25 in the first or closed position. FIG. 6 and FIG. 10 show views of controller arms in an extended position.
[0036] At the end of controller arms 25 is a controller arm wheel 27 , which is attached to controller arms 25 by a controller arm wheel standoff 26 . Controller arm wheel 27 is located inside a controller arm wheel rail 28 which allows movement of controller arm wheel 27 inside controller arm wheel rail 28 . Controller arm wheel rail 28 is attached to sliding mechanism bracket 23 by use of rivets 24 . Alternative attachment technologies could be used. In the current embodiment, rivet 24 is located on the cross section line as illustrated in FIG. 1 . Because of the lateral movement of sliding mechanism bracket caused when swing arms 12 are rotated outward, rivets 24 are no longer along the cross section line as illustrated in FIG. 2 .
[0037] A controller arm stopping block 66 is secured inside controller arm wheel rail 28 to prevent over extension of controller arms 25 and secure glass pane in second position. FIG. 9 and FIG. 10 illustrate that the controller arm stopping block 66 must be offset within the controller arm wheel rail 28 to allow for lateral displacement of glass pane 1 caused by the rotation of swing arms 12 .
[0038] In the first or closed position, glass pane 1 is securely held closed by the controller arms 25 as illustrated in FIG. 1 and FIG. 5 . Controller arms 25 also hold glass pane 1 securely when it is extended outside exterior window frame 2 when controller arms 25 are in an extended position as illustrated in FIG. 2 and FIG. 6 . In this second position as illustrated in FIG. 2 and FIG. 6 , air is allowed to enter through the gap formed between glass pane 1 and exterior window frame 2 .
[0039] FIG. 3 and FIG. 7 show glass pane 1 in the third position, extended outside exterior window frame 2 and over vehicle wall 5 , which allows a fully opened window and free flow of air through the window frame. Because of their telescopic nature, exterior sliding mechanism 19 and center sliding mechanism 18 are extended laterally, with exterior sliding mechanism 19 overlapping center sliding mechanism 18 , and center sliding mechanism 18 overlapping interior sliding mechanism 17 . Interior sliding mechanism 17 remains stable in the second position.
[0040] In the preferred embodiment, sliding handle 65 is attached to glass pane 1 by adhesive 22 , but could also be attached using bolts or other technologies. Sliding handle 65 has two functions. First, it is used to slide glass pane 1 from the second position to the third position, and second, it holds glass pane 1 securely in the first and third positions. As shown in FIG. 1 , FIG. 2 , and FIG. 4 , sliding handle 65 is held by first or closed position latch 64 . The entire latch assembly is a common technology and is essentially composed of latch rod 56 and latch spring 57 , which are held to upper perimeter controller frame 53 by latch clamps 55 . Rivets 58 attach latch clamps 55 to upper perimeter controller frame 53 , but other technologies such as bolts could be used.
[0041] In the preferred embodiment, upper perimeter controller frame 53 is made of the same material as lower perimeter controller frame 10 . It must be strong and not subject to significant deformation.
[0042] Latch spring 57 holds the first or closed position latch 64 in a closed position, which can be manually opened to allow movement of sliding handle 65 from the second position to the third position, and from third position back to second position. FIG. 4 and FIG. 5 show sliding handle 65 in the first or closed position. FIG. 6 shows sliding handle 65 in the second position, and FIG. 7 shows sliding handle 65 in the third position.
[0043] Sliding handle 65 is designed to ensure that glass pane 1 is held securely when glass pane 1 is moving between first or closed position and second position. FIG. 8 shows the contour of sliding handle 65 designed by calculating the lateral and outward movement as the swing arms 12 rotate while glass pane 1 moves from first or closed position to second position. The contour of sliding handle 65 is determined by the length of sliding handle 65 , and the sine and cosine of the angle of sliding handle 65 against lower perimeter controller frame 10 . When glass pane 1 moves from first or closed position to second position, the contoured edge of sliding handle 65 remains against the hooked edge of first or closed position latch 64 . This prevents glass pane 1 from sliding out of position and potentially damaging vehicle wall 5 as glass pane 1 transitions between first or closed position and second position.
[0044] To move glass pane 1 from second position to third position, first or closed position latch 64 is manually rotated to release sliding handle 65 which can now be moved laterally toward third position latch 68 . Third position latch 68 is designed so that sliding handle 65 is automatically secured by third position latch when moved to third position.
[0045] As shown in FIG. 1 and FIG. 2 , upper perimeter controller frame 53 is bent to provide two functions. First, the bends in upper perimeter controller frame 53 provides strength and rigidity. Upper perimeter controller frame 53 spans the entire length of the window opening as shown in FIG. 3 , and has the first or closed position latch 64 and third position latch 68 attached to it as shown in FIG. 4 . Manual movements of these latches requires that upper perimeter controller frame 53 have adequate strength. Second, the bend in upper perimeter controller frame 53 provides an overlap and resting place for center screen frame 52 .
[0046] Prevention of insects and debris from passing through the invention is essential. Because sliding handle 65 must be free to move between second and third positions, it is necessary to provide a barrier. In the preferred embodiment, sliding handle 65 passes between upper brush 62 and lower brush 63 . As illustrated in FIG. 1 and FIG. 2 , upper brush is attached to upper perimeter controller frame 53 with an adhesive 55 . Lower brush 63 is attached to controller screen frame 37 with an adhesive 59 . FIG. 3 and FIG. 4 show upper brush 62 and lower brush 63 spanning the length of the upper perimeter controller frame 53 to allow sliding handle 65 to fully open glass pane 1 .
[0047] Controller screen 36 prevents insects and debris from passing through the invention. FIG. 4 shows controller screen 36 secured by controller screen frame 34 , which completely outlines the perimeter. Controller screen 34 may be held securely in place by using clips or other means. In the present embodiment, controller screen is designed to cover screws 4 to provide a better cosmetic view.
[0048] Center screen 51 is secured by center screen frame 52 , which completely outlines the perimeter defined by the sides of interior window frame 3 and upper perimeter controller frame 53 . FIG. 4 shows the entire window assembly protected by screen. Center screen frame 52 would typically be attached to interior window frame 3 and upper perimeter controller frame 53 with the same technology used to attach controller screen frame 34 .
[0049] For further clarification of FIG. 1 and FIG. 2 , additional parts are labeled.
[0050] FIG. 3 and FIG. 4 show the complete window assembly, with the controlling mechanisms located on the top and bottom of the window assembly, providing a complete sealing of glass pane 1 to exterior window frame 2 . In alternative embodiments, the orientation of the opening of glass pane 1 could necessitate that the controlling mechanisms be located on other orientations of a window assembly, allowing glass pane 1 to open in non-horizontal directions.
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A window pane is mounted in a closed position outside a window frame, commonly referred to as a frameless window, and is movable into open positions parallel to the closed position. The window pane can be slid into a fully open position. Sliding mechanisms are attached to the window pane. Swing arms connect the sliding mechanisms to the window frame. Control arms also connect the sliding mechanisms to the window frame. They determine the distance of and control the translation of the window pan from the closed position to the initial open position. A handle is attached to at least one of the sliding mechanisms or window pane. Latching mechanisms secure the handle in the open positions. The invention is designed so that a plurality of screens allows air flow through the window frame, preventing passage of insects or debris through the window frame.
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BACKGROUND OF THE INVENTION
The present invention relates to converting pulverulent raw materials to a liquefied state as a first step in a melting process. The invention is particularly applicable to melting glass, including flat glass, container glass, fiber glass, and sodium silicate glass. But the invention is applicable to other processes that involve thermally converting a generally flowable, essentially solid state feed material to a molten fluid. These other processes may include metallurgical smelting type operations and fusing of single or multiple component ceramics, metals, or other materials. More particularly, this invention is an improvement in the invention disclosed in U.S. Pat. No. 4,381,934 and U.S. patent application Ser. No. 481,970 filed Apr. 4, 1983, both by G. E. Kunkle and J. M. Matesa.
Continuous glass melting processes conventionally entail depositing pulverulent batch materials onto a pool of molten glass maintained within a tank type melting furnace and applying thermal energy until the pulverulent materials are melted into the pool of molten glass.
The conventional tank type glass melting furnace possesses a number of deficiencies. A basic deficiency is that several operations, not all of which are compatible with one another, are carried out simultaneously within the same chamber. Thus, the melter chamber of a conventional furnace is expected to liquefy the glass batch, to dissolve grains of the batch, to homogenize the melt, and to refine the glass by freeing it of gaseous inclusions. Because these various operations are taking place simultaneously within the melter, and because different components of the glass batch possess different melting temperatures, it is not surprising that inhomogeneities exist from point to point within the melter.
In order to combat these inhomogeneities, a melting tank conventionally contains a relatively large volume of molten glass so as to provide sufficient residence time for currents in the molten glass to effect some degree of homogenization before the glass is discharged to a forming operation. These recirculating flows in a tank type melter result in inefficient use of thermal energy, and maintaining the large volume of molten glass itself presents difficulties, including the need to heat such a large chamber and the need to construct and maintain such a large chamber made of costly and, in some cases, difficult to obtain refractory materials. Moreover, erosion of the refractories introduces contaminants into the glass and requires rebuilding of the melter in a matter of a few years. Additionally, it is known that some components of the batch such as limestone, tend to melt out earlier than the sand and sink into the melt as globules, whereas higher melting temperature components, such as silica, tend to form a residual unmelted scum on the surface of the melt. This segregation of batch components further aggravates the problem of inhomogeneities.
Recent findings have indicated that a major rate limiting step of the melting process is the rate at which partly melted liquefied batch runs off the batch pile to expose underlying portions of the batch to the heat of the furnace. The conventional practice of floating a layer of batch on a pool of molten glass is not particularly conducive to aiding the runoff rate, due in part to the fact that the batch is partially immersed in the molten glass. It has also been found that radiant energy is considerably more effective at inducing runoff than is convective heat from the pool of molten glass, but in a conventional melter, only one side of the batch is exposed to overhead radiant heat sources. Similarly, conventional overhead radiant heating is inefficient in that only a portion of its radiant energy is directed downwardly towards the material being melted. Not only is considerable energy wasted through the superstructure of the furnace, but the resulting thermal degradation of the refractory roof components constitutes a major constraint on the operation of many glass melting furnaces. Furthermore, attempting to heat a relatively deep recirculating mass of glass from above inherently produces thermal inhomogeneities which can carry over into the forming process and affect the quality of the glass products being produced.
Many proposals have been made for overcoming some of the problems of the conventional tank type glass melting furnace, but none has found significant acceptance since each proposal has major difficulties in its implementation. It has been proposed, for example, that glass batch be liquefied on a ramp-like structure down which the liquid would flow into a melting tank (e.g., U.S. Pat. Nos. 296,227; 708,309; 2,593,197; 4,062,667; and 4,110,097). The intense heat and severely corrosive conditions to which such a ramp would be subjected has rendered such an approach impractical since available materials have an unreasonably short life in such an application. In some cases, it is suggested that such a ramp be cooled in order to extend its life, but cooling would extract a substantial amount of heat from the melting process and would diminish the thermal efficiency of the process. Also, the relatively large area of contact between the ramp and each unit volume of glass throughput would be a concern with regard to the amount of contaminants that may be picked up by the glass. Furthermore, in the ramp approach, heat transfer from a radiant source to the melting batch materials is in one direction only.
A variation on a ramp type melter is shown in U.S. Pat. No. 2,451,582 where glass batch materials are dispersed in a flame and land on an inclined ramp. As in other such arrangements, the ramp in the patented arrangement would suffer from severe erosion and glass contamination.
The prior art has also suggested melting glass in rotating vessels where the melting material would be spread in a thin layer on the interior surface of the vessel and would, more or less, surround the heat source (e.g., U.S. Pat. Nos. 1,889,509; 1,889,511; 2,006,947; 2,007,755; 4,061,487; and 4,185,984). As in the ramp proposals, the prior art rotary melters possess a severe materials durability problem and an undesirably large surface contact area per unit volume of glass throughput. In those embodiments where the rotating vessel is insulated, the severe conditions at the glass contact surface would indicate a short life for even the most costly refractory materials and a substantial contamination of the glass throughput. In those embodiments where the vessel is cooled on the exterior surface, heat transfer through the vessel would subtract substantial amounts of thermal energy from the melting process, which would adversely affect the efficiency of the process. In a rotary melter arrangement shown in U.S. Pat. No. 2,834,157 coolers are interposed between the melting material and the refractory vessel in order to preserve the refractories, and it is apparent that great thermal losses would be experienced in such an arrangement. In cyclone type melters, as shown in U.S. Pat. Nos. 3,077,094 and 3,510,289, rotary motion is imparted to the glass batch materials by gaseous means as the vessel remains stationary, but the cyclone arrangements possess all the disadvantages of the rotary melters noted above.
Some prior art processes conserve thermal energy and avoid refractory contact by melting from the interior of a mass of glass batch outwardly, including U.S. Pat. Nos. 1,082,195; 1,621,446; 3,109,045; 3,151,964; 3,328,149; and 3,689,679. Each of these proposals requires the use of electric heating and the initial liquefaction of the batch materials depends upon convective or conductive heating through the mass of previously melted glass. This is disadvantageous because radiant heating has been found to be more effective for the initial liquefaction step. Additionally, only the last two patents listed disclose continuous melting processes. In a similar arrangement disclosed in U.S. Pat. No. 3,637,365, one embodiment is disclosed wherein a combustion heat source may be employed to melt a preformed mass of glass batch from the center outwardly, but it, too, is a batchwise process and requires the melting to be terminated before the mass of glass batch is melted through.
The use of an electric plasma heat source (variously termed plasma arc, plasma jet, plasma torch) has long been recognized as desirable for melting applications because of the extremely high temperatures that can be attained. A major difficulty is providing a vessel that can withstand such high temperatures. Cooling of the melting vessel has been employed to reduce erosion of the vessel, but the resulting extraction of heat significantly reduces the thermal efficiency of the overall process. Therefore, plasma melting has been considered impractical for large scale commercial glass melting operations and the like.
An electric arc source can also generate extremely high temperatures, but a plasma heat source has advantages thereover in the type of melting process to which the present invention pertains. A cumbersome feature of an electric arc is that at least two electrodes must extend into the melting zone itself so that radiation from the arc directly impinges upon the material being melted. With a plasma torch, however, the plasma may be initiated outside the main melting zone and transported into the melting zone by means of the gas stream. Also, consumption of arc electrodes produces CO and/or CO 2 and can cause undesirable reduction reactions in the glass.
SUMMARY OF THE INVENTION
In the present invention, the initial step in a melting process, the liquefying of a raw material such as glass batch, is carried out by means of a plasma heat source. It has been found that a plasma heat source can be used to advantage in an ablating liquefaction process wherein the heat source is in a central cavity surrounded by a lining, at least the surface portion of which comprises a material of essentially the same composition as the raw material and/or the product. The raw material is fed at such a rate as to maintain a stable layer of the material encircling the heated cavity that is of sufficient thickness to insulate the underlying vessel structure from the heat without the need for forced cooling of the vessel. By permitting the liquefied material to flow out of the vessel as soon as it reaches a flowable condition, and by feeding additional raw materials onto the surface of the lining to replace the liquefied material flowing out, heat is quickly removed from the vessel at about the liquefying temperature of the material, and the lining temperature does not rise above that temperature regardless of the temperature of the heat source. Melting is substantially confined to a transient layer on the surface of the stable layer of the lining. Therefore, the very high temperature of a plasma heat source can be advantageously utilized for its high heat transfer rate to produce a large throughput without incurring contamination from contact with a refractory wall material, and without sacrificing efficiency by cooling the vessel.
THE DRAWINGS
FIG. 1 is a vertical cross-section of a preferred embodiment of the present invention wherein a drum rotating about a vertical axis of rotation provides a batch surface which is a paraboloid surface of rotation about a plasma heat source.
FIG. 2 is an enlarged cross-section of a specific embodiment of plasma torch that may be used with the present invention.
DETAILED DESCRIPTION
The invention will be described in conjunction with a preferred embodiment for melting glass, but it should be understood that the invention is not limited to the specific embodiment nor to the melting of glass.
Also, since the invention relates to the initial step of liquefying glass batch, the description of the embodiment will be limited to what would be only the initial portion of most glass melting operations. It should be understood that where the product requires, the inventive liquefaction step may be employed in combination with conventional means for further melting, refining, conditioning and forming the glass.
Glass batch liquefying means of various types that are compatible with the present invention are disclosed in U.S. Pat. No. 4,381,934 of G. E. Kunkle and J. M. Matesa, the disclosure of which is hereby incorporated by reference.
FIG. 1 shows a specific preferred embodiment of the present invention. In FIG. 1, a drum 30 has stepped sides so as to decrease the amount of mass being rotated. The drum could, of course, be a conical or cylindrical shape, but the stepped construction is preferred for ease of fabrication and reduced mass. The drum 30 is supported on a circular frame 31 which is, in turn, mounted for rotation about a generally vertical axis corresponding to the center line of the drum on a plurality of support rollers 32 and aligning rollers 33. A bottom section 35 houses an outlet assembly which may be detached from the remainder of the drum. The housing 35 may be lined with an annulus of refractory material 36 such as castable refractory cement in which is seated a ring-like bushing 37 of erosion resistant refractory. The bushing 37 may be comprised of a plurality of cut pieces of ceramic. An open center 38 in the bushing 37 comprises the outlet opening from the liquefaction chamber. An upwardly domed refractory lid 40 is provided with stationary support by way of a circular frame member 41. The lid includes an opening 42 for insertion of a plasma torch 43. In this embodiment the exhaust gases escape upwardly through an opening 44 through the lid 40 and into an exhaust duct 45. The opening 44 may also be utilized for feeding the raw materials to the liquefaction chamber, and a feed chute 50 may be provided for this purpose. The bottom end of the feed chute 50 may be provided with a movable baffle 51 for the purpose of controlling the location at which the raw materials are deposited into the liquefaction chamber. Upper and lower water seals 52 and 53 respectively, may be provided to isolate the interior of the liquefaction chamber from the exterior ambient conditions and to trap any dust or vapors that may escape from the vessel. A stable layer of unmelted material 54 is maintained within the liquefaction chamber and on this stable layer a transient layer 55 melts and flows downwardly through the bushing outlet 38. The liquefied material 56 then falls into a collection vessel 57.
In the liquefaction vessel of the present invention, the batch layer encircles the radiant heat source. Such an arrangement advantageously results in a greater portion of the radiant energy productively impinging upon the batch material and permits greater utilization of the insulative effect of the batch layer. Because the heat source is encircled by the insulating batch layer, refractory materials need not be employed for the sidewalls of the housing. Thus, the housing may comprise a steel vessel which may be provided with a frustoconical shape, which may be generally parallel to the interior surface of the batch layer. However, the sloped surface of the batch layer need not correspond to the shape of the housing, and the housing may take any form such as a cylindrical or box shape. A sloping, stable batch layer lines the sides of the interior of the liquefaction vessel and may be comprised of loose batch or a preformed, molded lining. As shown in the drawing, the surface of the batch layer facing the heat source is preferably a surface of rotation, in this case a generally paraboloid shape. Frusto-conical and cylindrical surfaces may also be employed. It may be also noted that the batch layer need not be of uniform thickness as long as the minimum thickness is sufficient to provide the desired degree of insulation. Because of the excellent insulating properties of glass batch, a stable batch layer whose minimum thickness is on the order of about 3 centimeters to 5 centimeters has been found more than adequate to protect a steel housing from undue thermal deterioration. A thickness of about 10 centimeters is preferred to provide a margin of safety.
In the preferred embodiment the vessel and the layer of material being melted is rotated about the heat source, but the rotation is not essential. Rotating the vessel is preferred because loose batch materials are held on the interior walls of the vessel facing the heated cavity at a more perpendicular attitude, thereby improving heat transfer. A steep batch surface also expedites draining of the liquefied material from the vessel. Rotating the vessel also simplifies distributing the feed stream around the interior of the vessel. A pre-molded batch layer, on the other hand, need not be rotated to provide a steep slope. In the preferred embodiment the axis of the drum and the coincident axis of rotation are vertical. But the axis in some cases may be inclined at an angle relative to vertical. The angle of incline of the rotating cylinder will be determined by the rate at which it is desired for the liquefied batch to run out of the cylinder. The cylinder should rotate at a speed at which loose batch is held against the inside walls by centrifugal force. The minimum speed will depend upon the effective diameter of the cylinder. The following are calculated estimates:
______________________________________Diameter Revolutions per Minute______________________________________0.5 Meters 601.0 Meters 432.0 Meters 37______________________________________
Before the vessel is heated, a stable layer of batch is provided in the vessel by feeding loose batch while the housing is rotated. The loose batch assumes a generally paraboloid contour as shown in FIG. 1. The shape assumed by loose, dry batch is related to the speed of rotation as follows:
H=μR+(2π.sup.2 ω.sup.2 R.sup.2)/g
Where:
H=the elevation of a point on the batch surface in the direction parallel to the axis of rotation;
R=the radial distance of that point from the axis of rotation;
μ=a friction factor;
ω=angular velocity; and
g=the acceleration of gravity.
The friction factor may be taken as the tangent of the angle of repose, which for dry glass batch is typically about 35°. The above equation may be employed to select suitable dimensions for the rotary vessel at a selected speed of rotation or, conversely, for determining a suitable speed of rotation for a given vessel. The relationship shows that steeper slopes, which are generally preferred, require faster rotational speeds, and that at zero velocity, the slope is determined solely by the angle of repose (assuming no preforming of the batch layer).
During heating, continuous feeding of batch to the vessel of FIG. 1 results in a falling stream of batch that becomes distributed over the surface of the stable batch layer, and by the action of the heat becomes liquefied in a transient layer 55 that runs to the bottom of the vessel and passes through opening 38. During operating, the rate of feeding the batch and the rate of heating are balanced against one another so that the batch layer remains stable and serves as the surface upon which newly fed batch is melted and runs toward the lower end of the cylinder. The liquefied batch falls as globules 56 from the exit opening and may be collected in a vessel for further processing.
Plasma heat sources are commercially available from a number of suppliers and vary in power level and configuration. The example of a plasma torch shown in the drawings is sold by Thermal Dynamics Corp., West Lebanon, N.H., under the name "Thermal Arc M-80 50N." The major structural components of the plasma torch are a cathode body 60 and an anode body 61 which may be bolted together. The cathode body 60 is a generally cylindrical member of electrical insulating material having a central bore 62 within which is received a cathode holder 63. The cathode holder 63 is connected to a cooling water supply conduit 64 which provides a flow of water (preferably de-ionized water) to annular passages 65 in the cathode holder. The cooling water escapes through a bore 66 in the side of the cathode body 60 and through a conduit 67. The conduit 67 carries the water to the anode body 61 where the water is circulated through annular passage 70. Another conduit (not shown) carries the water from the anode body 61 to a waste drain or heat exchanger for recycling.
A cathode 71 is received in a recess in the end of the cathode holder 63. A ring 72 of insulating material maintains the cathode spaced from the anode body. A gas supply conduit 73 is coupled to a bore 74 through the cathode body 60. The bore 74 leads to the interface between the anode body 61 and the ring 72 wherein there is provided an annular groove 75 and a plurality of tangential grooves in communication therewith so as to induce the gas to flow uniformly around the tip of the cathode 71 into the orifice 77 of the output nozzle as defined by an insert 78 held in the anode body 61.
Cathode 71 is connected to the negative side of a high voltage electric potential and the anode body 61 is connected to the positive side. An arc is created between the cathode 71 and the liner 78 across the path of the gas entering the nozzle 77. The arc excites atoms of the gas whereby they shed electrons and produce a plasma stream comprised of a mixture of ions, electrons, and sometimes neutral atoms. Intense energy is radiated from the plasma due to collisions among the highly excited particles and from recombination of electrons with the ionized atoms. The energy release from a plasma can be much greater than that from combustion. The onset of ionization is typically associated with localized temperatures in excess of 5,000° K., and thus a plasma heat source can be generally characterized by temperature of about 5,000° K. or greater.
Any inert gas may be used with the plasma torch such as argon, helium or nitrogen. Other gases which may be employed include oxygen, carbon monoxide, carbon dioxide and steam. Some gases, particularly oxidizing gases may require available torch designs other than the example shown and described here. Combustible gases such as hydrogen or methane may also be employed, in which case supplying oxygen to the plasma will produce combustion of the gas thereby yielding a combined energy release of the plasma and the combustion. The oxygen may be supplied outside the torch itself downstream fron the nozzle 77. Of particular interest in the melting of glass are helium and steam because of the relative ease with which bubbles of these gases may be dissipated in molten glass thereby easing the task of refining the glass. Moreover, the use of these easily refinable gases can serve to purge the cavity of the liquefaction chamber of more difficult to refine gases such as nitrogen and carbon dioxide so as to prevent their inclusion in the melt, further reducing the need for refining.
A melter using a conventional combustion heat source has a substantial throughput of gases whereby large amounts of energy are carried out of the melter in the exhaust gases. In a conventional glass melting furnace, the volume of the exhaust gases and the amount of energy being contained therein are such that a major expense of such furnaces is in providing heat recovery from the exhaust gases so as to recover some of the enormous amounts of energy that would otherwise be wasted. These heat recovery means (e.g, regenerators or recuperators) in addition to being costly are not as efficient in recovering energy as would be desired. For a given amount of energy output a plasma heat source entails only a fraction of the gas throughput of a fuel/air combustion heat source, and even somewhat less than a fuel/oxygen combustion heat source. Therefore, much less heat is conveyed out of the melting zone by the exhaust gases when a plasma heat source is being used, thus reducing the extent of heat recovery means required for acceptable overall process efficiency.
Plasma torches are available in a variety of sizes and configurations and with varying maximum power levels. Selection of an appropriate plasma torch for a particular application is within the ordinary skill of the art and will depend upon the amount of heat required to liquefy the particular batch material being treated, the desired throughput rate, and the size of the liquefaction vessel.
In a typical glass batch formula consisting primarily of sand, soda ash and limestone, the soda ash begins to melt first, followed by the limestone, and finally the sand. Physical melting is accompanied by chemical interactions, in particular, the molten alkalis attack the sand grains to effect their dissolution at a temperature below the melting point of silica. At some intermediate point in this process, the liquid phase of the heterogeneous mixture of reacting and melting materials begins to predominate and the material becomes flowable as a fluid. The temperature at which the batch becomes flowable will depend upon the particular batch formula, especially the amount and melting temperature of the lowest melting temperature ingredients. The most common low temperature melting ingredient is soda ash, which melts at 1564° F. (851° C.). Theoretically, a batch having a sufficient amount of soda ash may become liquefied at the soda ash melting temperature, but experience with commercial batch formulas indicates that the temperature is somewhat higher--2000° F. (1090° C.) to 2100° F. (1150° C.) for a typical flat glass batch. This may be explained by the fact that batch melting is a complex series of interactions among the various ingredients, whereby the physical properties of the individual ingredients are not exhibited. It may also be that insufficient soda ash is present when melted to entrain by itself the remainder of the unmelted materials. Moreover, even though the present invention eliminates much of the overheating of conventional melters, the runoff temperatures observed with the present invention may not truly represent the initiation of liquefaction, but may include a small amount of heating after liquefaction. Other low temperature melting ingredients sometimes employed in glass batches, such as caustic soda and boric acid, have even lower melting temperatures than soda ash and may behave differently as runoff initiators. On the other hand, some types of glass other than flat glass require higher temperatures to melt. For many types of glasses made on a large scale commercially, the present invention would be expected to operate satisfactorily with liquefied batch draining from the liquefaction chamber at about 1600° F. (870° C.) to 2400° F. (1315° C.).
In the present invention, the liquefied batch drains from the liquefaction zone as soon as it reaches the fluid state, and therefore the fluid draining from the liquefaction zone has a nearly uniform temperature close to the liquefying temperature of the particular batch formula, typically about 2100° F. (1150° C.) in the case of conventional flat glass. Because heat is transported out of the liquefaction zone at the liquefying temperature, which is considerably lower than the temperatures attained in a conventional glass melter, the temperature of the liquefaction vessel may be maintained relatively low regardless of the temperature of the heat source. As a result, materials requirements may be reduced relative to a conventional melter, and use of high temperature heat sources is made possible. The greater heat flux afforded by high temperature heat sources advantageously increases the rate of throughput. The use of a plasma torch is also advantageous in the present invention for the sake of reducing the volume of combustion gases, thereby decreasing any tendency of the fine batch materials to become entrained in the exhaust gas stream. This is particularly significant in the preferred practice of feeding the batch dry to the liquefaction vessel as opposed to the conventional practice of wetting the batch with water to inhibit dusting.
An example of a batch formula employed in the commercial manufacture of flat glass is the following:
______________________________________Sand 1000 parts by weightSoda ash 313.5Limestone 84Dolomite 242Rouge 0.75______________________________________
The above batch formula yields approximately the following glass composition:
______________________________________SiO.sub.2 73.10% by weightNa.sub.2 O 13.75%CaO 8.85%MgO 3.85%Al.sub.2 O.sub.3 0.10%Fe.sub.2 O.sub.3 0.10%______________________________________
The liquefied batch running out of the liquefaction zone of the present invention, when using the batch formula set forth above, is predominantly liquid (weight basis) and includes about 15% by weight or less of crystalline silica (i.e., undissolved sand grains). The liquid phase is predominantly sodium disilicate and includes almost the entire soda ash portion of the batch and most of the limestone and dolomite. The fluid, however, is quite foamy, having a density typically on the order of about 1.9 grams per cubic centimeter, as opposed to a density of about 2.5 grams per cubic centimeter for molten glass.
Although the description of the invention heretofore has related specifically to liquefying glass batch, it should be apparent that the principles of the invention may apply to other materials as well, particularly materials that are initially in a flowable solid form (i.e., granular or pulverulent) and are thermally meltable to a flowable fluid state. Flowability is a desirable characteristic of the feed material for the sake of distributing the material onto the melting surface within the liquefaction chamber. Typically the feed will chiefly comprise subdivided solids, but may include a liquid portion. It is also within the scope of the invention to feed a plurality of streams into the liquefaction chamber, some of which may be liquids. In general, the combined feed for use in the present invention may be characterized as having a greater frictional resistance to flow down the surface of the stable layer than does the liquefied material. Thus, the material initially remains exposed to the heat until it becomes liquefied, whereupon it flows out of the liquefaction zone. Combinations of properties analogous to those in the liquefaction of glass batch may be found in the fusing of ceramic materials and the like and in metallurgical smelting type operations.
Whatever material is being processed, the vessel is insulated from the interior heat by a substantially stable layer of essentially the same material maintained on the interior of the vessel. It is desirable for the thermal conductivity of the material employed as the stable layer to be relatively low so that practical thicknesses of the layer may be employed while avoiding the need for wasteful forced cooling of the vessel exterior. In general, granular or pulverulent mineral source raw materials provide good thermal insulation, but in some cases it may be possible to use an intermediate or product of the melting process as a non-contaminating stable layer. For example, in a glassmaking process, pulverized cullet (scrap glass) could constitute the stable layer, although a thicker layer would be required due to the higher thermal conductivity of glass as compared to glass batch. In metallurgical processes, on the other hand, using a metallic product as the stable layer would entail unduly large thicknesses to provide thermal protection to the vessel, but some ore materials may be satisfactory as insulating layers.
In commercial glassmaking operations, glass batches often include substantial amounts of cullet, or scrap glass. The present invention can accommodate conventional cullet-containing batches, and could be used to melt cullet alone. The cullet may be mixed with the other batch constituents prior to feeding, or the cullet may be fed into the liquefaction zone as a separate stream.
A feature of the invention is that melting takes place in a transient layer that is supported by and flows on a stable layer. It should be understood that the terms "transient" and "stable" are relative, and that a distinct physical demarcation between the transient and stable layers may not always be identifiable. The use of the terms "transient" and "stable" is not intended to preclude the possibility that minor fluctuation of the interface therebetween may occur. The basic distinction is that the region that is described as the transient layer is characterized by melting and flowing, whereas the region termed the stable layer, in at least its major portion, does not participate in the melting and flowing of the thoughput stream. Although the transient layer is said to be "on" the stable layer, one might theoretically define an intermediate layer therebetween, and it should be understood that that possibility is intended to be included. For example, it would be within the ambit of the invention as expressed to feed a plurality of constituents in a stratified manner onto the melting surface.
A purpose of the stable layer is to provide non-contaminating contact with the throughput stream. Therefore, the stable layer is preferably of essentially the same composition as the material being processed. However, it should be understood that precursor or derivative materials would be considered "essentially the same composition" in this context. In other words, the stable layer could be the raw material, the product material, an intermediate, or a different form or mixture thereof, as long as it melts or reacts to form a substance that does not introduce significant amounts of foreign constituents into the throughput stream. It should also be evident that this compositional requirement of the stable layer need apply only to surface portions that actually contact the throughput stream and to portions just under the surface that may occasionally erode into the throughput stream. Therefore, an equivalent arrangement might employ a different material in portions of the stable layer below the level at which erosion is likely to occur. Since this subsurface portion serves primarily as insulation to protect the vessel, it could be composed of a material selected for its thermal insulating properties (e.g., sand or ceramic particles), although it should be sufficiently compatible compositionally to not contaminate the surface layer at the temperatures involved.
Other modifications and variations as would be obvious to those of skill in the art may be resorted to without departing from the scope of the invention as defined by the claims which follow.
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Converting thermally meltable materials to a liquefied state is carried out by a plasma heat source encircled by a layer of the unmelted material. As liquefied material is drained from the surface, additional unmelted material is fed onto the surface to maintain a substantially constant layer of the unmelted material, thereby maintaining the temperature of the melting vessel relatively low and eliminating the need for forced cooling of the vessel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional and claims the priority benefit of U.S. patent application Ser. No. 10/359,359, filed Feb. 4, 2003 and entitled “Managing Users in a Multi-User Network Game Environment,” which claimed the priority benefit of U.S. Provisional Patent Application Ser. No. 60/376,115, entitled “Multi-User Application Program Interface”, filed Apr. 26, 2002, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to computer networks and, more particularly, to balancing distribution of participants in a gaming environment over a computer network.
[0004] 2. Description of the Related Art
[0005] Computer networks, such as local area networks and the Internet, are increasingly being used as the backbone for various transactions and interactions between parties. From online banking, where bank customers can initiate financial transactions over a computer network, to online gaming, where garners can participate in real-time gaming over the Internet, service providers are increasingly supporting a variety of services over computer networks. There are currently a variety of different computer network configurations that facilitate the transactions and interactions that take place.
[0006] Many of the online applications involve multi-user applications, which are computer programs that are executed on a computer system and which allow multiple geographically separated participants to interact with the computer program and other participating users in an application environment. For example, gaming is a popular multi-user application that is increasing in popularity. An aircraft simulation game can enable multiple participants to pilot their respective virtual aircraft within an airspace, and can enable the participants to interact with other participants in their aircraft in the same airspace. Thus, the online gaming application provides a single application environment or universe in which multiple participants maneuver.
[0007] To support multi-user applications, such as online gaming, with geographically dispersed application users, such as game participants, and to support real-time interaction among the users in the application environment, it has been necessary to share information about every participant in the environment. For example, in an aircraft simulation application, it becomes necessary to share information about the airplanes for each of the participants, including aircraft size, speed, altitude in three-dimensional space, appearance details, virtual environment details (such as buildings and terrain), and the like. Such information permits the computer at each participant to properly keep track of game developments and determine the actions being performed by each of the participants. This permits each participant to obtain properly rendered visual images on the participant's viewing display.
[0008] The amount of information that must be shared among all of the participants can become daunting and can result in bandwidth difficulties. The amount of information that must be shared among participants is so great that it has inhibited the development of online gaming and other online multi-user applications. A technique for distributing the management of online applications is described in U.S. Pat. No. 5,841,980 to R. Waters et al. entitled Distributed System for Communication Networks in Multi-User Applications.
[0009] The '980 patent describes a system configuration in which the functionality of a monolithic server is distributed across multiple servers, each of which services a number of local users. Thus, whereas a single server previously served as the source of all application information, such as game state, the '980 patent describes a situation in which the game server functionality is distributed across multiple computers. Users (on-line participants) are free to login to their most convenient server. In this way, there is no single “choke point” that might inhibit game play, and the bandwidth requirements for the online game community are reduced. Even with the reduction in overall bandwidth demands, the sheer volume of data that must be transmitted between users to support the online environment can result in local pockets of strained bandwidth capacity.
[0010] Other multi-user applications provide a somewhat cumbersome user interface and can be inefficient for operation of the application server. For example, some online gaming portals provide links to game sites of interest. The server that provides the gaming portal Web site only provides links to game pages or game Web sites. Thus, the gaming portal will redirect a user to the appropriate game server or host for information about ongoing games. This places additional operational burdens on the game servers.
[0011] Unfortunately, current multi-user applications are not configured for maximum efficiency of operation and cannot support a number of application users to make online gaming a viable opportunity. Thus, there is a need for an improved, more efficient online multi-user application environment. The present invention satisfies this need.
SUMMARY OF THE INVENTION
[0012] The present invention provides for balancing distribution of participants in a gaming environment. In various embodiments, systems of the present invention may include multiple application servers each hosting a common game application, a lobby server for assigning new client devices to one of the application servers, and a universe manager for receiving reports from each of the application servers concerning the status of the game application. The universe manager may further instruct the lobby server to reallocate assignment of subsequent new client devices in order to balance the number of client devices assigned to each application servers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an illustration of a computer network system on which is run a multi-user application configured in accordance with the present invention.
[0014] FIG. 2 is a detail block of the system shown in FIG. 1 .
[0015] FIG. 3 is a flow diagram of the operations performed by the system of FIG. 1 .
[0016] FIG. 4 is a flow diagram that shows further system operations in addition to those shown in FIG. 3 .
[0017] FIG. 5 is a flow diagram that shows further system operations in addition to those shown in FIG. 3 .
[0018] FIG. 6 is a block diagram of a computer in the network illustrated in FIG. 4 , illustrating the hardware components.
[0019] FIG. 7 is a block diagram of a computer entertainment system in the network illustrated in FIG. 1 , illustrating the hardware components.
DETAILED DESCRIPTION
[0020] System Construction
[0021] FIG. 1 is a block diagram of a computer network system 100 comprised of one or more network devices including one or more client computers 102 who communicate with an authorization server 104 to gain access to the system, including participation with multi-user online applications. As described further below, the client computers can comprise computers 102 ( a ) configured in a classic client-server configuration, or in a peer-to-peer configuration, or can comprise computers 102 ( b ) configured in an integrated server configuration that combine the functionality of other computers with the client computer functions. References to client computers 102 will be understood to be a collective reference to either configuration, or references to one configuration subgroup 102 ( a ), 102 ( b ) or the other will be to the specific subgroup specified. An authentication server determines whether authorization is warranted by consulting a database server 106 for user records. The authentication server also communicates with a universe manager computer 108 that maintains records about online users and helps manage the online application environment, or universe.
[0022] After an authentication server 104 authorizes a user 102 to continue, the user can participate in an online multi-user application by first communicating with lobby servers 110 to obtain application-level information. The application-level information can include information about an application and its participating users. In the context of an online game application, for example, the lobby server 110 can provide information about the game and about currently participating users. After selection of an online multi-user application, the user is redirected to an appropriate application server 112 , from which the user receives information sufficient to permit the user to join the online environment of the multi-user application. Thus, application level information is maintained at a lobby server 110 , rather than at each individual application server or host machine 112 . Users can therefore learn about and select a desired application, such as an aircraft online game, through communication with the lobby server, leaving the application servers free to host their particular applications.
[0023] In FIG. 1 , the lobby servers 108 and application servers 112 are depicted as cloud shapes to indicate that the functionality of these servers can be distributed across multiple computers who collectively provide the functionality or can be provided by one or more independent network computers. For example, the application servers 112 can comprise dedicated application server computers 114 that function as a distributed memory engine (DME). As an alternative, as described further below, the application servers can comprise a combination of integrated servers 102 ( b ) and application servers 112 acting in a proxy capacity to provide an interface to the universe manager 108 . Similarly, the function of the lobby servers 110 can be provided by dedicated lobby servers that communicate directly with the clients 102 , or the lobby server functions can be provided by other computers that communicate with the clients, such as the authentication server or universe manager 108 .
[0024] Thus, the functionality of the game server is split between the lobby server and the application server. The lobby server can therefore reduce the bandwidth requirements and other operating demands on the application server. The application can comprise, for example, a multi-user interactive gaming application. This improves efficiency of operation.
[0025] In accordance with the invention, cross-user communications as well as cross-application communications in real-time are facilitated through the lobby server concept. A user who is participating with one application can communicate with a user who is participating with a different application. Thus, a first user can be logged in to lobby server and can be participating in an aircraft online game environment through an application server, while a second user can be logged in to the same lobby server, but can be participating with a different application in a different programming environment, such as a financial package or a different online game. The first user and the second user can communicate with each other, if they wish, or they can choose to participate in their respective environments, isolated from each other in terms of communications.
[0026] The universe manager 108 acts in an overall supervisory role, maintaining information about the users (clients) 102 who are registered with the system and logged on, communicating with the users via the authorization servers 104 , lobby servers 110 , and application servers 112 . The lobby servers 110 provide application level information to the users, thereby acting as an application portal and source of application information to the clients 102 . For example, unlike typical game portal servers that merely provide links to game sites, the lobby servers provide information about games in progress and can provide game-level information, such as information about the players who are actively participating in a game. The application servers 112 provide the actual application environment. For example, in the situation where the online application is a game, the application servers provide the actual game play environment comprising player participants, audio and graphics information, and other data necessary for a client 102 to fully participate in the online gaming experience for the game administered by the particular application server 112 . In this way, many tasks that must be performed to support system operation can be performed according to the most appropriate machine to perform the task.
[0027] As noted above, the authentication servers 104 communicate with database servers 106 for authentication, application information, and the like. FIG. 2 illustrates details of the database servers and shows that the database servers can comprise multiple servers and associated database storage. For example, FIG. 2 shows a database server 106 that includes an authentication data server 202 and an associated authentication database 204 , a transaction data server 206 and associated transaction database 208 , and an application data server 210 and associated application database 212 . The operation and configuration of these components will be better understood with reference to the following description.
[0028] System Operation
[0029] FIGS. 3 , 4 , and 5 are flow diagrams that illustrate the functioning of the system constructed in accordance with the invention to provide improved operation of online multi-user applications.
[0030] In the first operation, represented by the flow diagram block 301 , a user connects to a network domain name, such as a game portal or other Internet site to attempt access and login to a multi-user application, such as an online game. In the next operation, the user is redirected to one of the authentication servers. This operation (represented by block 302 ) can include operation through a load balancer or similar configuration for server workload management. At the next block 303 , the user is assigned a session key by an authentication server. The session key will remain active during the current online session by the user and will be associated with a privilege level, thereby providing a means for the various system components (illustrated in FIG. 1 ) to determine the level of access to be granted to the user. The user then supplies account login information to the authentication server, at block 304 , and then the authentication server forwards an authentication request to the authentication data server (of the database servers), as indicated at the block 305 . The account login involves a user's registered account number or other identifier against which a user's right to access can be determined. At the next operation (block 306 ), the authentication request is processed with appropriate load balancing and is directed to a particular one of the authentication servers.
[0031] At the next block 307 , the authentication data server communicates directly with the authentication database to determine whether the user's login should be accepted. This operation can involve, for example, checking the user's account history to ensure all appropriate fees have been paid and to ensure the user has all authorizations or qualifications to proceed. To maintain the user's history, this operation 307 also involves sending the transaction record (login attempt) to the transaction data server for non-volatile storage. This recording operation also can involve a load balancing operation.
[0032] The success or failure of the login attempt is reported back to the authentication server, at the next block 308 . The login result is forwarded back to the user and also to the transaction data server. At the next block 309 , similar processing operations are repeated for the user name login procedure. Yet another similar login sequence occurs for the user's screen name, along with an application identification, as indicated at the block 310 . If the screen name login is successful, then the authentication server will assign the user to a lobby server and will also promote the session privilege level to the Universe Manager, so that the user will be granted all appropriate access during the session. It should be noted that the authentication server is aware of the lobby servers that are available corresponding to the application ID provided by the user, by requesting an appropriate application server from the Universe Manager. The Universe Manager keeps track of the available lobby servers via “heartbeat” reports that are sent by lobby servers to the Universe Manager continuously while the lobby servers are operational. This processing is represented by the next block 310 .
[0033] Next, at the block 311 , the user disconnects from the authentication server and establishes communication with the assigned lobby server. At the block 312 , the user verifies the session key that was obtained from the authentication server at block 303 and also verifies the application ID with the assigned lobby server. The lobby server verifies the data, as well as the privilege level, with the Universe Manager. The user's privilege is upgraded upon successful verification.
[0034] In the next phase of system operation, at block 313 , the user has successfully completed login with a lobby server and therefore is entitled to participate in system-wide functions. These functions can include, for example, chat, group or community management, player-matching activities such as team or clan tasks, and outcome or competitive standings and ladder progress. Any requests from the user for information regarding available chat channels, available games, location of other users, messaging functions, and the like, the request is forwarded from the lobby server to the Universe Manager. If a request for information involves the non-volatile storage, then the request is forwarded to the appropriate database server ( FIG. 2 ).
[0035] One of the system-wide functions that a user might want to participate in following successful connection with a lobby server can comprise using an application. In the context of an online gaming environment, that application is a game. Those skilled in the art will appreciate that other online multi-user applications can be involved. As noted above, the clients can participate in online gaming as either part of a client-server configuration or peer-to-peer configuration, or as part of an integrated application server and client configuration. FIG. 4 relates to users who are operating in a client-server or peer-to-peer configuration, and FIG. 5 relates to users who are operating in an integrated application server configuration.
[0036] In FIG. 4 , the first operation (which occurs upon the user wanting to join a game after completion of the last block in FIG. 3 ), is for the lobby server to forward the user's application (game) request to the Universe Manager. In the FIG. 4 processing, the client is configured as a classic client-server configuration or as a peer-to-peer configuration. The Universe Manager assigns the user to a game server that is appropriate for the requested game. The game servers keep the Universe Manager apprised of their status via continuous, periodic heartbeat reports, in a fashion similar to that of the lobby servers. In this way, the Universe Manager is aware of system status and can manage and respond to requests from the lobby servers and application servers. After the first processing operation shown in FIG. 4 (block 414 ), the assigned application server assigns a server specific key to the user (block 415 ). The key provides an extra measure of security to prevent unauthorized access. The authentication server asks either the Universe Manager or the assigned application server for the key, and forwards the key to the user through the Universe Manager and to the lobby server.
[0037] In the next block 416 , the user is connected with the assigned application server, providing it with the server-specific key it received from block 415 . The user will be disconnected from the application server if the server-specific key does not match the records at the application server. If there is a match, the user is allowed to remain connected with the application server. It should be noted that the user remains connected to a lobby server throughout use of the application, such as during a game playing session. At block 417 , periodic user reports are sent from an application-participating user back to the user's lobby server. In addition, the application server who is hosting the application for all participants (such as the game host) sends periodic reports on the status of the application to the application host. The lobby server and application server do not directly communicate, thereby better managing the processing load on the lobby server.
[0038] At the conclusion of the application session (block 418 ), the user disconnects from the application server and returns to normal activities, including all available lobby functions through the lobby server. As noted, these functions can include chat, group or community management, messaging, and the like. It should be noted that these functions are available to the user at all times when the user is connected to the lobby server, including during application use (e.g., during game play).
[0039] If the user performs a logout procedure, or if the user is timed out from an active connection because of inactivity, the user's session is cleared from the active records of the Universe Manager. This is indicated at the next block, 419 . If the user wishes to participate in another application, the user must go through the authentication process once again, including the login process.
[0040] Rather than operate in a network configuration in which applications are provided by dedicated application servers, the network can also operate in a configuration in which the multi-user application is provided by integrated servers. An integrated server refers to a user (client) machine that has been configured with an integrated server application that provides the user machine with application server functionality. A system that implements this method of operation is described in co-pending U.S. patent application Ser. No. 09/704,514 by C. Guy, G. Van Datta, and J. Fernandes entitled “Application Development Interface for Multi-User Applications Executable Over Communication Networks” filed Nov. 1, 2000. The disclosure of this application is hereby incorporated by reference. As noted above, when a user wants to join a game, the system operation moves from the description of FIG. 3 to the description of either FIG. 4 (dedicated application server) or FIG. 5 (integrated server).
[0041] Turning now to FIG. 5 , the first operation under the integrated server configuration is for a user who wants to host an application (such as an online game) to initialize an integrated server application that has been installed on the user's computer. The integrated server application makes a connection to an appropriate domain name, such as a game portal Web site. The integrated server then executes an authentication process with an authentication server, in a process similar to the initial login process described in conjunction with FIG. 3 . These operations are represented by the first block 514 of FIG. 5 .
[0042] Upon successful authentication with the authentication server, the hosting user's integrated server application causes periodic server reports to be transmitted to a proxy application server. As noted above, the proxy application server is included within the application server cloud 112 of FIG. 1 . The proxy application server can comprise an application in addition to or integrated with the integrated server application at the hosting user, or the proxy application server can comprise a separate server that is another node of the FIG. 1 network and that communicates with the hosting user's computer. In any case, the user's integrated server application provides periodic, regular “heartbeat” reports to the proxy application server to confirm the operation of the hosted application and to provide status information to the proxy application server. The proxy application server communicates with the Universe Manager, providing the Universe Manager with the application status information received from the hosting user machine. The Universe Manager includes these reports in its data collection, just as it would with similar reports from dedicated application servers and from any other integrated servers. These reporting operations are represented by the second block 515 of FIG. 5 .
[0043] In the next operation, block 516 , the user notifies its assigned lobby server of its status as an active application server. This new executing application will now be available over the network. The lobby server then registers this new application with the Universe Manager, which adds the appropriate application information to its data collection. This operation is performed by the Universe Manager in a manner similar to what it would perform in response to any other server becoming available with a network application.
[0044] After the new application has been registered with the Universe Manager, the network nodes will become aware of the application through respective lobby servers. Therefore, the application becomes available for network users, who can join the program environment established by the integrated server. For example, if the application is a multi-user game, then other network users can join the on-going game, as managed by the hosting user's integrated server. The process of joining a game in progress involves the same operations as described above in conjunction with blocks 414 , 415 , 416 , and 417 of FIG. 4 . These operations involve communicating with an appropriate application server, receiving a server-specific key, providing the server with that key, becoming authorized and providing regular “heartbeat” reports to the lobby server. These integrated server operations are represented by the “join” block 517 of FIG. 5 .
[0045] At the conclusion of the application session (block 518 ), a participating user can disconnect from the integrated server and return to normal activities, including all available lobby functions through the lobby server. As noted, these functions can include chat, group or community management, messaging, and the like. As noted above, these functions are available to the user at all times when the user is connected to the lobby server, including during application use (e.g., during game play). If a hosting user (the integrated server) wishes to withdraw from hosting the application, the network system ( FIG. 1 ) can implement procedures as desired to ensure an orderly shut down of the application or an orderly transition to a different integrated server that continues on with the program environment of the hosted application.
[0046] If the user performs a logout procedure, or if the user is timed out from an active connection because of inactivity, the user's session is cleared from the active records of the Universe Manager. This is indicated at the next block, 519 . If the user wishes to participate in another application, the user must go through the authentication process once again, including the login process.
[0047] Ladder Ranking
[0048] The application program interface that is shared in common with all the components illustrated in FIG. 1 also includes provision for a ladder ranking engine. A ladder ranking is a list of users that is organized or sorted according to a predetermined variable or metric. The ladder ranking is most easily understood in the context of a gaming application, where the predetermined variable likely refers to wins, losses, points scored, and the like. As a user improves his or her performance, the user's ranking will improve, meaning that the user will move up a “ladder” of ranked users. Thus, the ladder ranking information can be used for various competitive purposes, such as contests and tournaments.
[0049] The ladder ranking information is collected via functionality in each multi-user application that periodically reports the application status to the corresponding application server. The status can include information such as progress of players in the game. The application servers then store the information to a system database that is indexed according to a user's account information and application currently being used. This information is managed by a ladder engine that can operate at any location of the network, for example, at the Universe Manager, and the data can be stored at data storage of the Universe Manager or in the database servers ( FIG. 1 ).
[0050] The system interface preferably provides for any registered user to request a ladder ranking, which will be provided through the ladder ranking engine. The request can come from a user via an application with which the user is currently participating. This ensures that non-participants cannot falsely obtain the ladder ranking information. The ladder ranking requests can be received by a lobby server or application server from a user, and the request can be forwarded to the ladder ranking engine at the Universe Manager or whatever other network entity that manages the ladder rankings. When a ladder ranking list is requested, all of the user accounts for the specified application are sorted based on the stored user performance data. The application status information preferably includes multiple statistics, which can be stored simultaneously in the database. For example, a gaming application can track wins, losses, points scored, points allowed, and other performance statistics of interest. Each metric can be sorted on, thus generating a ladder ranking according to the metric chosen by the user who requests the ladder ranking. Moreover, the ladder ranking engine provides sorting and retrieving of a ladder ranking in ascending or descending order. For example, a ladder ranking can be provided in order from most points to least points, or from least points to most points.
[0051] The various servers and databases of the system have no knowledge about the nature of the statistics. That is, the servers do not examine the underlying data to understand the difference between wins and losses or points and goals. Rather, the various applications define the data set to be collected for that application, and the servers and databases simply store the collected data in the database. Thus, each application will define its own data collection format, which will be supported by the database servers.
[0052] The data can be included in a 256-byte data field that is assigned to each user's account for each application with which the system interfaces. For example, the application code can execute the ladder ranking function by specifying data parameters of sort order, start byte, end byte. Upon receiving a ladder ranking message with these parameters, a server or database of the system will retrieve all data fields for all accounts associated with the calling application. The data in each data record between the start byte location and the end byte location will be treated as an integer value. The sort operation will then be performed on the retrieved data, in ascending or descending order depending on the value of a user-supplied sort order parameter. The sorted integer numbers can then be displayed to a user in accordance with known headings for the integer data. For example, a particular application might store performance data as number of wins, followed by number of losses, followed by points scored, followed by points allowed. When the performance data is retrieved, the data can be parsed to extract the requested data for proper display. Other applications can store different performance parameters in a different order, which will be known to the corresponding application server. In this way, the ladder ranking engine provides a powerful generic, cross-application ladder rankings system.
[0053] Clans Engine
[0054] Another feature of the system described herein is a clans engine that allows a designated user of any trusted application, a user referred to as a “leader”, to name and create a clan. The leader can then issue invitations to other users for joining the clan. The system will queue up any invitations sent to registered users who are not online at the time the invitation is sent, for delivery at the invitee's next login. A user who receives a clan invitation can respond affirmatively or negatively and, if desired, can become a member of the clan.
[0055] The system supports a variety of clan features. Members of a clan can send private electronic messages to the members of the clan. The clan messages can be stored on the servers of the system until delivery, which occurs as each member completes the next login process. The system permits clans to elect new leaders and set up various organizational structures for their clan. Examples of organizational structures include dictatorships, where one leader is in charge of all decisions of the clan, or a democracy, where all members and the leader have equal votes in the clan decision making. The leader who initiates the clan can select which of these, or other, configurations will be utilized.
[0056] All of the various clan data, including the clan membership list, clan activity tracking, clan electronic messaging, and the like are saved by database servers of the system. The clan functionality is accessed through the program interface in accordance with the present invention, in a manner similar to that described above for the ladder ranking data. This permits many discrete functions to be provided and specified or deleted for each clan, making the composition rules and operation of each clan potentially exclusive. Moreover, the program interface permits the clan functionality to be used in a generic way for multiple applications. For example, in a gaming context, the same team or clan functionality can be applied whether the application is a flight simulator, car racing game, or action-shooter game.
[0057] In addition, multiple applications can share the same clans and membership servers and databases at the same time, without interfering with each other. User accounts can be associated with more than one clan in the same application or in clans that extend across multiple applications, without any impact to the user account or to the clan functionality.
[0058] The clan engine in accordance with the present invention manages the clan data using server-side processing, rather than relying on offline, Web-based clan management techniques or client-side arbitration, with nothing built into the actual application itself. Thus, any application developed for the program interface described herein can utilize the clan processing that is built into the interface specification, servers, and databases of the FIG. 1 system.
[0059] Network Device Construction
[0060] The network computer devices (clients and servers) shown in the block diagram of FIG. 1 comprise nodes of a computer network system 100 . FIG. 6 is a block diagram of a computer in the system 100 of FIG. 1 , illustrating the hardware components included in one of the computers that provide the functionality of the servers and clients. Those skilled in the art will appreciate that the servers and clients illustrated in FIG. 1 can all have a similar computer construction, or can have alternative constructions consistent with the capabilities and respective functions described herein.
[0061] FIG. 6 shows an exemplary computer 600 such as might comprise any of the network computers. Each computer 600 operates under control of a central processor unit (CPU) 602 , such as a “Pentium” microprocessor and associated integrated circuit chips, available from Intel Corporation of Santa Clara, Calif., USA. A computer user can input commands and data from a keyboard and computer mouse 604 , and can view inputs and computer output at a display 606 . The display is typically a video monitor or flat panel display. The computer 600 also includes a direct access storage device (DASD) 608 , such as a hard disk drive. The memory 610 typically comprises volatile semiconductor random access memory (RAM). Each computer preferably includes a program product reader 612 that accepts a program product storage device 614 , from which the program product reader can read data (and to which it can optionally write data). The program product reader can comprise, for example, a disk drive, and the program product storage device can comprise removable storage media such as a magnetic floppy disk, a CD-R disc, a CD-RW disc, or DVD disc.
[0062] Each computer 600 can communicate with the others over a computer network 620 (such as the Internet or an intranet) through a network interface 618 that enables communication over a connection 622 between the network 620 and the computer. The network interface 618 typically comprises, for example, a Network Interface Card (NIC) or a modem that permits communications over a variety of networks.
[0063] The CPU 602 operates under control of programming steps that are temporarily stored in the memory 610 of the computer 600 . When the programming steps are executed, the computer performs its functions. Thus, the programming steps implement the functionality of the respective client or server. The programming steps can be received from the DASD 608 , through the program product storage device 614 , or through the network connection 622 . The program product storage drive 612 can receive a program product 614 , read programming steps recorded thereon, and transfer the programming steps into the memory 610 for execution by the CPU 602 . As noted above, the program product storage device can comprise any one of multiple removable media having recorded computer-readable instructions, including magnetic floppy disks and CD-ROM storage discs. Other suitable program product storage devices can include magnetic tape and semiconductor memory chips. In this way, the processing steps necessary for operation in accordance with the invention can be embodied on a program product.
[0064] Alternatively, the program steps can be received into the operating memory 610 over the network 620 . In the network method, the computer receives data including program steps into the memory 610 through the network interface 618 after network communication has been established over the network connection 622 by well-known methods that will be understood by those skilled in the art without further explanation. The program steps are then executed by the CPU 602 thereby comprising a computer process.
[0065] It should be understood that all of the network computers of the network system 100 illustrated in FIG. 1 can have a construction similar to that shown in FIG. 6 , so that details described with respect to the FIG. 6 computer 600 will be understood to apply to all computers of the system 100 . It should be appreciated that any of the network computers can have an alternative construction, so long as the computer can communicate with the other computers illustrated in FIG. 4 and can support the functionality described herein.
[0066] For example, with reference to FIG. 7 , the client computers 102 can comprise a computer entertainment system, such as a video game console system 700 . FIG. 7 is a block diagram of an exemplary hardware configuration of the video game console system 700 .
[0067] The video game console system 700 includes a central processing unit (CPU) 701 that is associated with a main memory 705 . The CPU 701 operates under control of programming steps that are stored in the OS-ROM 760 or transferred from a game program storage medium to the main memory 705 . The CPU 701 is configured to process information and execute instructions in accordance with the programming steps.
[0068] The CPU 701 is communicatively coupled to an input/output processor (IOP) 720 via a dedicated bus 725 . The IOP 720 couples the CPU 701 to an OS ROM 760 comprised of a non-volatile memory that stores program instructions, such as an operating system. The instructions are preferably transferred to the CPU via the IOP 720 at start-up of the main unit 700 .
[0069] The CPU 701 is communicatively coupled to a graphics processing unit (GPU) 710 via a dedicated bus 715 . The GPU 710 is a drawing processor that is configured to perform drawing processes and formulate images in accordance with instructions received from the CPU 701 . For example, the GPU 710 can render a graphics image based on display lists that are generated by and received from the CPU 701 . The GPU can include a buffer for storing graphics data. The GPU 710 outputs images to an AV output device 790 that is connected to the console system 700 .
[0070] The IOP 720 controls the exchange of data among the CPU 700 and a plurality of peripheral components in accordance with instructions that are stored in an IOP memory 730 . The peripheral components can include one or more input controllers 722 , a memory card 740 , a USB 745 , and an IEEE 1394 serial bus 750 . Additionally, a bus 755 is communicatively coupled to the IOP 720 . The bus 755 is linked to several additional components, including the OS ROM 760 , a sound processor unit (SPU) 765 , an optical disc control unit 775 , and a hard disk drive (HDD) 780 .
[0071] The SPU 765 is configured to generate sounds, such as music, sound effects, and voices, in accordance with commands received from the CPU 701 and the IOP 720 . The SPU 765 can include a sound buffer in which waveform data is stored. The SPU 765 generates sound signals and transmits the signals to speakers.
[0072] The disc control unit 775 is configured to control a program reader, which can comprise, for example, an optical disk drive that accepts removable storage media such as a magnetic floppy disk, an optical CD-ROM disc, a CD-R disc, a CD-RW disc, a DVD disk, or the like.
[0073] The memory card 740 can comprise a storage medium to which the CPU 701 can write and store data. Preferably, the memory card 740 can be inserted and removed from the IOP 720 . A user can store or save data using the memory card 740 . In addition, the video game system 700 is preferably provided with at least one hard disk drive (HDD) 780 to which data can be written and stored.
[0074] A data I/O interface, such as an IEEE 1394 serial bus 750 or a universal serial bus (USB) 745 interface, is preferably communicatively coupled to the IOP 720 in order to allow data to be transferred into and out of the video game system 700 , such as to the network illustrated in FIG. 1 .
[0075] The present invention has been described above in terms of a presently preferred embodiment so that an understanding of the present invention can be conveyed. There are, however, many configurations for the system and application not specifically described herein but with which the present invention is applicable. The present invention should therefore not be seen as limited to the particular embodiment described herein, but rather, it should be understood that the present invention has wide applicability with respect to multi-user applications generally. All modifications, variations, or equivalent arrangements and implementations that are within the scope of the attached claims should therefore be considered within the scope of the invention.
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Systems for balancing distribution of participants in a gaming environment are provided. In various embodiments, systems of the present invention may include multiple application servers each hosting a common game application, a lobby server for assigning new client devices to one of the application servers, and a universe manager for receiving reports from each of the application servers concerning the status of the game application. The universe manager may further instruct the lobby server to reallocate assignment of subsequent new client devices in order to balance the number of client devices assigned to each application servers.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to provisional U.S. patent application entitled, RATCHET DRIVER AND METHOD OF MAKING SAME, filed Jul. 19, 2005, having a Ser. No. 60/700,195, the disclosure of which is hereby incorporated by reference in its entirety.
Also, this relates to U.S. patent application Ser. No. 10/746,633, filed Dec. 29, 2003 and issued as U.S. Pat. No. 6,997,084 B1. There is common inventorship and a common owner for the present application, the above-referenced application, and the above-referenced patent. The disclosures of the above-referenced application and patent are incorporated into this present disclosure.
FIELD OF THE INVENTION
Certain embodiments of the present invention relate generally to ratchet drivers and to methods of making ratchet drivers. More particularly, certain embodiments of the present invention relate to ratcheting drivers which have pivotal pawls. The invention is particularly applicable to ratchet screwdrivers and also where there are two pawls which are pivotal between the driving and released positions for respective rotation inducement and free ratcheting movement.
BACKGROUND OF THE INVENTION
Ratcheting drivers are currently available to those skilled in applying fasteners, and in performing like actions. Such drivers commonly include a handle and an actuator thereon. Such drivers also commonly include a driven gear and pawl assembly, all for maneuvering the actuator for selectively setting the assembly for rotational driving in either direction while allowing ratcheting in the direction opposite the driving direction.
SUMMARY OF THE INVENTION
At least one embodiment of the present invention improves upon currently-available drivers by presenting a ratcheting driver which firmly transmits an optimum amount of torque through the gear and pawl assembly. In accomplishing this objective, the driver according to this embodiment is relatively easily manufactured, inexpensive, durable, can be miniature, and is reliable.
In using a ratcheting driver, torque is typically applied from a user's hand to the handle, then to the pawl, then to the gear, and then to the driven tool bit and/or to the work piece (e.g., a screw, nut, or bolt). According to certain embodiments of the present invention, it is important to have the assembly arranged for optimum transmission of the applied hand torque. Such optimization is often dependent upon the construction, mounting, and location of the pawls. Certain embodiments of the present invention achieve the optimum arrangement for transmitting that optimum torque, and do so in a reliable and consistent manner.
Certain embodiments of the present invention include pivotal pawls which are supported in pockets of the driver handle and, under the force of the rotation torque being applied, the pawls cannot then pivot out of their engaged position with the gear. That is, according to certain embodiments of the present invention, the rotation force applied through the handle serves to secure the pawls in the engaged position. As such, according to these embodiments, there is a relationship between the handle and the pawls to effect the securement of the engaged pawls without any forces tending to tilt the pawl. According to these embodiments, the torquing force, as applied to the pawls themselves, serves to enhance security for the engagement of the teeth which will remain engaged while driving.
According to certain embodiments of the present invention, the pawls have a stability with the handle and the gear to always remain aligned therewith and thereby have full and aligned contact with the gear during maximum torque transmission. Also, according to some of these embodiments, in the driving mode, the forces on the pawls from the handle are in a direction to enhance the force of engagement of the pawl with the gear teeth to thereby remain in full and secure driving contact. In fact, according to certain embodiments of the present invention, there can be more than one angular direction of the forces from the handle to the pawl, and thus there can be, for example, two simultaneously applied forces from the handle to the engaged pawl. Those two forces may, for example, be applied to spaced-apart locations, both of which urge the pawl into firm tooth engagement with the gear, as is desired.
Another important feature of certain embodiments of the present invention is that, in these embodiments, the pawls are disengaged from the gear by a camming action applied by a control that slidably engages the pawls for pivoting the pawls off the gear to thereby disengage the pawls. In such an arrangement, the control is selectively moved to respective positions relative to the respective pawl to pivot the prawl off of the gear. In that action, the control and the pawl have mutually engaging surfaces for effecting the pivoting action, and that produces the camming action.
As will be appreciated by those of skill in the art, that is in contrast to currently available practice of pushing pawls out of the way to free the pawls from gear engagement. As such, currently available pawls are tenuously positioned in their engaged positions. In contrast, according to certain embodiments of the present invention, the disengaging force on the pawl is in a direction of a force-component radially directed relative to the longitudinal axis of the gear.
Regarding the foregoing, according to certain embodiments of the present invention, the pawls can extend axially beyond the length of the gear teeth, and an actuator web is arranged for pivoting the pawl off of the gear from underneath the pawl. That is, according to some of these embodiments, the web extends to a location radially inward on the pawl to lift the pawl off the gear.
The driver cap according to certain embodiments of the present invention has a web which serves to rotationally release the pawls, so no additional pawl actuator member is required to serve as a pawl release. According to some of these embodiments, release is accomplished with one integral cap with a web which pivots the respective pawls off of the gear.
Additionally, according to certain embodiments of the present invention, the pawls are utilized for limiting the rotation of the cap when using the cap for ratcheting and driving adjustments. According to some of these embodiments, the pawls themselves are placed in rotative obstruction so the cap cannot be rotated too far until the cap is intentionally released.
According to still other embodiments of the present invention, the gear is rotatably supported at its two ends which flank the gear teeth. Therefore, according to some of these embodiments, the tendency to cock or tilt currently available gears is eliminated because the gear according to certain embodiments of the present invention is held stable against the driving forces. Also, according to certain embodiments of the present invention, the pawls extend beyond the axial length of the gear teeth, and thusly the web which actuates by pivoting the pawls can contact the pawls from underneath at the extending lengths to lift the pawls for pivoting. This is in direct contrast to pushing the pawls off to one side, as is currently done.
Further, according to certain embodiments of the present invention, the driver provides for precision and, therefore, firm gear teeth engagement between the handle carrying the two pawls and the driven gear. The gear may be small, at least relative to currently available ratchet drivers. Also, the ratio of gear teeth to base diameter of the gear may be high compared to currently available drivers. Thus, the teeth for engagement between the handle and the gear are, according to certain embodiments of the present invention, relatively numerous and small or fine for quiet, smooth, precise and close engagement, all with a lack of tooth play, while transmitting high torque.
The aforementioned are accomplished, according to certain embodiments of the present invention, because of an intimate engagement between the driving handle and each of the two pawls. According to certain embodiments of the present invention, the pawls and the handle have matching surfaces which are in extended contact when a pawl is in the torque driving mode. As such, according to certain embodiments of the present invention, more than a line contact therebetween transmits the torque to the pawls and then to the gear. According to certain embodiments of the present invention, those surfaces face tangentially to the gear at the point of tooth engagement, thereby transmitting torque at the optimum leverage and to the gear. Also, the matching surfaces may be arcuate and have a common center of curvature to produce the extended surface contact therebetween.
Also, according to certain embodiments of the present invention, a spring is applied for alternately urging the pawls into engagement with the gear. In some of these embodiments, the spring relates to the pawls in a self-adjusting contact with the pawls by sliding thereon, as needed. When one pawl is mechanically disengaged from the gear, the spring, according to certain embodiments of the present invention, automatically responds and is thus pressed to thereby exert an increased force on the other pawl. In some of these embodiments, the spring slides on both pawls for self-positioning of the spring on the two pawls.
Though certain embodiments of the present invention include two pivoting pawls, there is typically a firm stop action effective on the pawls when they are pivoted out of gear release mode. A line abutment, and that is firm, may also be applied between the pivoting pawls and the handle.
As will be appreciated by one of skill in the art, certain of the aforementioned embodiments of the present invention permit providing a miniature driver. This miniature driver is typically sensitive, strong, and smooth in its ratcheting action.
According to other embodiments of the present invention, a method of arranging one or more drivers according to certain embodiments of the present invention is also provided. Such a method is typically efficient and frequently presents a sturdy driver. Also considered to be part of certain embodiments of the present invention is the control of the parts during assembly so that the pawls and a cap release are properly positioned so that the cap can be released when desired. Further, according to certain embodiments of the present invention, the cap has a restrictor thereon to preclude incorrect rotation of the cap on the handle for assembly of the cap thereon. That is significant because, according to certain embodiments of the present invention, the cap includes a projection or web that is preferably positioned between the two pawls for proper pawl tooth release of the pawls from the gear.
There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
As such, 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, methods 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.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of an assembled driver according to one embodiment of the present invention.
FIG. 2 is a front end elevational view of FIG. 1 , on a reduced scale.
FIG. 3 is a sectional view taken on a plane designated by the line 3 - 3 in FIG. 2 .
FIG. 4 is a exploded view of the driver illustrated in FIG. 1 .
FIG. 5 is a side elevational view of FIG. 1 , on a reduced scale.
FIG. 6 is an enlarged section view taken on a plane designated by the line 6 - 6 of FIG. 5 .
FIG. 7 is an enlarged perspective view of a part seen in FIG. 4 .
FIG. 8 is an end elevational view of FIG. 7 .
FIG. 9 is perspective view like FIG. 7 , but with parts added thereto.
FIG. 10 is an end elevational view of FIG. 9 .
FIG. 11 is a perspective view like FIG. 9 but with a part removed.
FIGS. 12 and 13 are respectively perspective and end elevational views of the cap part in FIG. 4 .
FIGS. 14 and 15 are respectively perspective and front elevational views of a pawl seen in FIG. 11 .
DETAILED DESCRIPTION
Certain embodiments of the present invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout.
FIG. 1 is a front perspective view of an assembled driver 10 (e.g., a screwdriver) according to one embodiment of the present invention. FIG. 1 illustrates that the driver 10 includes an elongated housing in the form of a handle 11 that is also illustrated in FIGS. 1-4 . FIG. 1 also illustrates that the screwdriver 10 includes an attachment 12 , which serves as a pawl positioner or actuator and that the attachment 12 , along with other internal parts of the driver 10 , are all oriented along a longitudinal axis A.
According to certain embodiments of the present invention, the driver 10 is a miniature screwdriver. Thus, the handle 11 illustrated in FIGS. 1-4 has a substantially spherical- or pear-shaped exterior shape to facilitate gripping by the palm of an operator's hand. The precision and the efficient transmission of rotation torque applied by the operator's hand allows for the miniature configuration which is shown in the above-discussed figures. However, other shapes and sizes are also within the scope of certain embodiments of the present invention.
The attachment 12 included in the handle 11 is illustrated in FIG. 4 as being threaded and that can thus be screwed into the handle 11 . More specifically, as illustrated in FIG. 3 , a portion of the attachment 12 includes threads 13 and may be rotated (i.e., screwed) as a unit into the pear-shaped handle portion 11 . The attachment 12 therefore presents an integral and fixed connection as a part of and with the remainder of the handle 11 . As shown in FIG. 4 , once the handle 11 and attachment 12 are connected to each other, the combination includes an axially extending hollow interior 14 and two pawl pockets 16 .
As also illustrated in FIG. 4 , according to certain embodiments of the present invention, a cylindrical spur gear member 17 that includes spur gear teeth 18 is rotationally snugly assembled with (i.e., screwed into) the handle 11 in the interior 14 . The gear 17 typically has both of its axially extending ends 19 snugly rotationally supported in the interior 14 .
FIG. 4 also illustrates a collet member 21 that is suitably rotationally connected to the gear member 17 . The collet member 21 illustrated includes jaws 22 for clamping onto a work piece (not illustrated). The work piece may take the form of, for example, a screw, bolt, nut, or other rotational fastener or member which is to be driven by the driver 10 .
The above-discussed handle 11 can rotate or orbit the pawl pockets 16 about the axis A in both directions and relative to the gear member 17 . The pockets 16 are typically disposed radially outwardly of the gear teeth 18 and can rotate therearound.
To induce rotation of the gear member 17 and consequent similar rotation of the collet member 21 , two pawls 23 and 24 are pivotally disposed in the respective pockets 16 and are disposed generally radially of the circumference of the gear teeth 18 , as seen in FIG. 6 .
A cylindrical cap 26 that is cup-shaped and that fits over the axial end of the handle 11 is illustrated at least in FIGS. 1 , 4 , and 8 . The cap 26 includes three radially extending tangs 27 which serve as bayonet connectors with the three tangs 28 on the handle 11 . Thus, according to certain embodiments of the present invention, the cap 26 can be moved axially onto the handle portion 12 and then rotated to bayonet-engage the cap 26 onto the handle 11 . The cap 26 typically includes has a rim therearound, and there is typically included a web or projection which is pear-shaped in axial views thereof and that extends inwardly from the rim and to a location between the pawls 23 and 24 . This location is also within the height of the gear teeth 18 , as illustrated in FIG. 6 .
As illustrated in FIGS. 9 and 11 , the pawls 23 and 24 extend beyond the axial extent of the gear teeth 18 and beyond the planar wall 32 of the handle 11 . Thus, according to certain embodiments of the present invention, the pawls 23 , 24 present an extension or overhang in their lengths and, upon rotation of the cap 26 , as the cap 26 is rotationally piloted on the housing, the above-discussed web or projection engages those overhanging ends of the pawls 23 and 24 and thereby pivots the pawls 23 , 24 out of engagement with the gear member 17 and/or gear teeth 18 , as selected.
The above-discussed attachment 12 has its two pawl pockets 16 in what is seen as the upper half of the portion 12 , as seen in FIG. 8 . Those pockets 16 are, according to certain embodiments of the present invention, mirror images of each other, and they both typically include three circular outwardly extending and arcuate pockets 34 , 36 , and 37 , each one being essentially semi-circular in axial view per FIG. 8 . The pockets 34 , 36 , and 37 are typically open to the central opening 14 .
The two pawls 23 and 24 are typically identical to each other in shape in axial view, and they substantially match the shape of the pockets 16 in axial view. As illustrated in FIG. 15 , the pawls 23 , 24 have a central portion 38 and two opposite end portions 39 and 41 . The central portion 38 is typically a fulcrum or pivot portion and, as shown in FIG. 15 , can be at least substantially semi-circular and snugly slidable in and conforming to the shape of the semi-circular pocket portion 36 . The two pawl end portions 39 and 41 are respectively disposed in the pockets 34 and 37 . As such, the pockets 16 and the pawls 23 and 24 are, according to certain embodiments of the present invention, substantially T-shaped in the axial view.
The pawl portions 39 have spur teeth 42 facing the gear teeth 18 . The locations of gear tooth engagement are typically at the respective 10/11 O'clock and 1/2 O'clock locations, as illustrated in FIG. 10 , and these engagements are labeled 43 and 44 . Typically, each of these engagements comprehends a circumferential length of several teeth on the gear member 17 and, of course, also with regard to the gear-engaged teeth 42 on the pawls 23 , 24 .
The handle 11 typically has a concave and at least approximately semi-circular surface 46 , as shown herein, defining a pocket 34 and centered about the pawl pivot axis P. Each pawl 23 , 24 is shown to have a convex at least approximately semi-circular surface 47 of the same size and shape as the surface 46 and fully overlying and fully flush with the housing surface 46 . Therefore, the two surfaces are defined as being matingly matched. Also for each pawl 23 , 24 , the housing has a concave at least approximately semi-circular surface 48 . Each pawl 23 , 24 has a convex at least approximately semi-circular surface 49 fully overlying and fully flush with the housing surface 48 in the pawl tooth-engaged mode, and therefore being defined as being matingly matched, as seen in FIGS. 6 and 10 .
Each pocket 16 is defined by an arcuate concave surface 51 , centered on the pivot axis P and which extends contiguous with each pocket 16 surface 48 and presents a sliding surface for sliding contact by the pawl end 52 for approximately ten degrees of pivot sliding of the pawl on the surface 51 . In that sliding action, the pawls swing or pivot about the axis P and between gear tooth engaged mode and gear tooth released mode, as shown respectively with the pawls 24 and 23 in FIGS. 6 and 10 .
With regard to both surfaces 46 and 48 , they face the tooth engaged locations 43 and 44 . One of skill in the art will appreciate that there are imaginary straight lines between each of those surfaces and the respective tooth-engaged locations. One of skill in the art will also appreciate that those lines are respectively at least substantially tangential to the gear teeth 18 . This results in the line of rotation force creating the torque which is applied through the handle 11 and is thus applied at an optimum angle onto the gear 17 for optimum torquing effect. Also, in and during the driving mode, both surfaces 46 and 48 are simultaneous applied to the respective pawl so there is firm and full application of the operator's hand rotation action applied onto the gear 17 .
As discussed above, each pawl 23 and 24 includes at least three portions: the central pivot portion 38 , the engageable end portion 41 , and the opposite end portion 39 . Typically, the two end portions 39 , 41 are swingable in the handle pocket openings 16 and the handle surface 48 extends into the length 51 , which is centered about the pivot axis P. Thus, according to certain embodiments of the present invention, the pawls 23 , 24 are securely retained in the respective housing pockets 16 while being free to swing toward and away relative to the gear member 17 at the two opposite ends 39 and 41 of each pawl 23 , 24 . That is, the pawls 23 , 24 typically have convex tips 52 slidable on the arcuate housing surfaces 51 which are centered on pivot axis P. The housing has surfaces 51 and 53 centered about axis P, and these surfaces 51 , 53 typically face each other to thereby restrict the pawls from moving out of the handle pockets 16 because the pawls have ends 52 and 50 in respective sliding contact with those surfaces 51 and 53 .
Further, when a pawl is in the full gear tooth released mode, as with the pawl 23 illustrated in FIG. 10 , there is a line contact at 54 on the pawl and a surface 56 defining the pocket 33 . That gives a firm and definite stop point for the pivot of the release pawl.
The representative arrangement described above regarding the full surface engagement between the pawls and the handle as at surfaces 46 and 48 of the handle, produces a triangle of force application with the respective tooth-engaged locations.
According to certain embodiments of the present invention, the cap 26 is suitably limitedly or restrictively rotatably attached to the handle, and the cap 26 may be in any conventional attachment arrangement, such as the bayonet type attachment arrangement shown where the flanges 27 and 28 interengage in the conventional manner to axially fix the cap 26 relative to the handle but to also allow a slight rotational movement of the cap 26 . Also, according to certain embodiments of the present invention, the cap 26 is releasably retained in any one of three rotated positions for determining the ratcheting and drive directions. Those positions are typically established by a pin 57 which is yieldingly urged axially leftward in FIG. 1 by spring 58 to sequentially seat the pin 57 into a selected one of the three holes 59 in the cap 12 . That adjustment is simply a self-releasing over-ride arrangement so that the cap can be rotated over the pin 57 to any one of the three positions.
The rotation of the cap is typically limited by the pawls 23 and 24 which are axially positioned to interfere with the web 29 in the rotation of the cap. While both pawls 23 and 24 typically extend into the cap 26 , the pawl 23 can be of a shorter length and is urged into the cap 26 by a spring 61 illustrated in FIG. 1 . In such an arrangement, the pawls 23 and 24 can be of different lengths, and the pawl 24 is shown in FIG. 2 to be longer. As such, it fully occupies the length, or depth, of its pocket 16 and extends therebeyond, as seen in FIGS. 9 and 11 . However, the pawl 23 can be of a shorter length. In such arrangements, it does not fully occupy the axial length of its pocket 16 which accommodates the spring 61 and, under the urging of the spring 61 , pawl 23 extends beyond the length of the gear teeth 18 , as does the pawl 24 . Also, according to certain embodiments of the present invention, the pawls extend beyond the handle wall 32 .
In assembling the driver 10 , the cap 26 is typically axially moved onto the housing 12 and the cap web 29 is disposed between the pawls. With assembly positioning of the bayonet projections, namely offset from each other, the web 29 is aligned with the forces down on the spring-urged pawl 23 and, upon rotation of the cap out of that positioning, the pawl 23 is released and the web 29 is rotated to a position between the pawls 23 and 24 which are then in the arcuate path of rotation of the web to thereby preclude over-rotation of the cap relative to the handle.
According to certain embodiments of the present invention, an access hole 62 in the cap 26 permits the insertion of a pin (not illustrated) into the cap and onto the pawl 23 to push the pawl 23 against the spring 54 , thereby permitting the cap to be rotated beyond the pawl 23 and off of the bayonet connection of the cap 26 with the handle 12 and for disassembly.
In assembly, according to certain embodiments of the present invention, there is a fixed projection 63 on the handle 12 extending into the cap 26 . The projection 63 typically provides rotation interference upon rotation of the cap 26 and its web 29 which can abut the projection 63 . Thus, the cap typically cannot be over-rotated in the counterclockwise direction, as viewed in FIG. 6 . Also, while assembling the driver 10 , the web 29 will, according to certain embodiments of the present invention, always be properly positioned between the pawls and will not rotate therebeyond.
According to certain embodiments of the present invention, a spring 64 is coiled and piloted on the pin 57 on the handle. The spring typically has two legs 67 extending respectively into contact with the pawls 23 and 24 . The spring tips 68 are typically angulated and in sliding contact with the pawl concave surfaces 69 and therefore are self-adjusting along those surfaces in response to pivot action of the pawls. The spring 64 illustrated herein has its two legs 67 tensioned for exerting radially outward force on the pawls. Therefore, when one pawl is spring-forced out of gear tooth engagement by the cap web doing so, the spring 64 is placed under tension such that the other spring leg receives an increased force to urge and hold the other pawl into gear tooth engagement, as seen in FIG. 6 . When such an arrangement with the pawls 23 and 24 is implemented, the spring legs 67 are typically always in sliding contact with the pawl surfaces 69 to pivotally urge the pawls 23 and 24 toward and sometimes into tooth engagement with the gear teeth 18 , as illustrated in FIGS. 6 and 10 .
The web 29 is typically shaped to cam under the pawls 23 and 24 so that, upon rotation of the cap 26 , the pawl is disengaged from the gear 18 , as illustrated in FIG. 6 . With that maneuver, where the cap 26 has been rotated clockwise from the handle end, the drive is also typically clockwise.
According to certain embodiments of the present invention, there are two substantially handle T-shaped pockets 16 with the central portion 34 and the two flanking arm portions 36 and 37 , all forming a substantially right angled relationship of the T-shape upright stem and then to cross bar at right angles to that stem. Likewise, the two pawls are typically at least substantially T-shaped to at least substantially conform to the shape of the handle pockets 16 and be matingly matched therewith. According to certain embodiments of the present invention, there are two rotation drive surfaces 46 and 48 on the handle 12 , and they both apply a drive torque tangential to the gear teeth 18 . In that arrangement, the gear teeth can be small and the drive is firm and precise without lost drive motion between the handle and the gear. With the surfaces 48 and 49 , they are of two dimensional flush and overlying contact with each other, and that is defined as being substantially devoid of only line contact.
One representative method of arranging a tool (e.g., the screwdriver 10 ) is disclosed in this description. This method typically includes the arrangement with the pawls and the spring 67 and the cap rotation and the positioning of the web between the pawls for cap rotation restrictions. It also typically includes the release of the cap from its restricted rotation, all as described herein. However, other methods are also within the scope of the present invention.
The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated 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 ratcheting driver configured to rotationally drive an item or work piece is provided. The driver includes a handle and pivotal pawls engageable with a driven gear and capable of ratcheting and driving in both rotational directions. The handle and pawls have mating matched surfaces for full and flush overlying contact therebetween. A cap that is rotatable relative to the handle and that has a web for pivoting the pawls out of engagement with the gear is also provided. In addition, a stop is included. The stop is configured to assure that only a correct direction of rotation of the cap is available when assembling. Also, a method of arranging the driver is provided.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of and claims priority from U.S. patent application Ser. No. 10/404,270 filed on Mar. 31, 2003, and entitled, “Vertical Proximity Processor” which is a continuation-in-part and claims priority from co-pending U.S. patent application Ser. No. 10/330,843 filed on Dec. 24, 2002 and entitled “Meniscus, Vacuum, IPA Vapor, Drying Manifold,” which is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/261,839 filed on Sep. 30, 2002 and entitled “Method and Apparatus for Drying Semiconductor Wafer Surfaces Using a Plurality of Inlets and Outlets Held in Close Proximity to the Wafer Surfaces,” both of which are incorporated herein by reference in its entirety. This application is related to U.S. patent application Ser. No. 10/330,897, filed on Dec. 24, 2002, entitled “System for Substrate Processing with Meniscus, Vacuum, IPA vapor, Drying Manifold” and is also related to U.S. patent application Ser. No. 10/404,692, filed on Mar. 31, 2003, entitled “Methods and Systems for Processing a Substrate Using a Dynamic Liquid Meniscus.” The aforementioned patent applications are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to semiconductor wafer cleaning and drying and, more particularly, to apparatuses and techniques for more efficiently removing fluids from wafer surfaces while reducing contamination and decreasing wafer cleaning cost.
[0004] 2. Description of the Related Art
[0005] In the semiconductor chip fabrication process, it is well-known that there is a need to clean and dry a wafer where a fabrication operation has been performed that leaves unwanted residues on the surfaces of wafers. Examples of such a fabrication operation include plasma etching (e.g., tungsten etch back (WEB)) and chemical mechanical polishing (CMP). In CMP, a wafer is placed in a holder which pushes a wafer surface against a rolling conveyor belt. This conveyor belt uses a slurry which consists of chemicals and abrasive materials to cause the polishing. Unfortunately, this process tends to leave an accumulation of slurry particles and residues at the wafer surface. If left on the wafer, the unwanted residual material and particles may cause, among other things, defects such as scratches on the wafer surface and inappropriate interactions between metallization features. In some cases, such defects may cause devices on the wafer to become inoperable. In order to avoid the undue costs of discarding wafers having inoperable devices, it is therefore necessary to clean the wafer adequately yet efficiently after fabrication operations that leave unwanted residues.
[0006] After a wafer has been wet cleaned, the wafer must be dried effectively to prevent water or cleaning fluid remnants from leaving residues on the wafer. If the cleaning fluid on the wafer surface is allowed to evaporate, as usually happens when droplets form, residues or contaminants previously dissolved in the cleaning fluid will remain on the wafer surface after evaporation (e.g., and form spots). To prevent evaporation from taking place, the cleaning fluid must be removed as quickly as possible without the formation of droplets on the wafer surface. In an attempt to accomplish this, one of several different drying techniques are employed such as spin drying, IPA, or Marangoni drying. All of these drying techniques utilize some form of a moving liquid/gas interface on a wafer surface which, if properly maintained, results in drying of a wafer surface without the formation of droplets. Unfortunately, if the moving liquid/gas interface breaks down, as often happens with all of the aforementioned drying methods, droplets form and evaporation occurs resulting in contaminants being left on the wafer surface.
[0007] The most prevalent drying technique used today is spin rinse drying (SRD). FIG. 1 illustrates movement of cleaning fluids on a wafer 10 during an SRD drying process. In this drying process, a wet wafer is rotated at a high rate by rotation 14 . In SRD, by use of centrifugal force, the water or cleaning fluid used to clean the wafer is pulled from the center of the wafer to the outside of the wafer and finally off of the wafer as shown by fluid directional arrows 16 . As the cleaning fluid is being pulled off of the wafer, a moving liquid/gas interface 12 is created at the center of the wafer and moves to the outside of the wafer (ie., the circle produced by the moving liquid/gas interface 12 gets larger) as the drying process progresses. In the example of FIG. 1 , the inside area of the circle formed by the moving liquid/gas interface 12 is free from the fluid and the outside area of the circle formed by the moving liquid/gas interface 12 is the cleaning fluid. Therefore, as the drying process continues, the section inside (the dry area) of the moving liquid/gas interface 12 increases while the area (the wet area) outside of the moving liquid/gas interface 12 decreases. As stated previously, if the moving liquid/gas interface 12 breaks down, droplets of the cleaning fluid form on the wafer and contamination may occur due to evaporation of the droplets. As such, it is imperative that droplet formation and the subsequent evaporation be limited to keep contaminants off of the wafer surface. Unfortunately, the present drying methods are only partially successful at the prevention of moving liquid interface breakdown.
[0008] In addition, the SRD process has difficulties with drying wafer surfaces that are hydrophobic. Hydrophobic wafer surfaces can be difficult to dry because such surfaces repel water and water based (aqueous) cleaning solutions. Therefore, as the drying process continues and the cleaning fluid is pulled away from the wafer surface, the remaining cleaning fluid (if aqueous based) will be repelled by the wafer surface. As a result, the aqueous cleaning fluid will want the least amount of area to be in contact with the hydrophobic wafer surface. Additionally, the aqueous cleaning solution tends cling to itself as a result of surface tension (ie., as a result of molecular hydrogen bonding). Therefore, because of the hydrophobic interactions and the surface tension, balls (or droplets) of aqueous cleaning fluid forms in an uncontrolled manner on the hydrophobic wafer surface. This formation of droplets results in the harmful evaporation and the contamination discussed previously. The limitations of the SRD are particularly severe at the center of the wafer, where centrifugal force acting on the droplets is the smallest. Consequently, although the SRD process is presently the most common way of wafer drying, this method can have difficulties reducing formation of cleaning fluid droplets on the wafer surface especially when used on hydrophobic wafer surfaces.
[0009] Therefore, there is a need for a method and an apparatus that avoids the prior art by allowing quick and efficient cleaning and drying of a semiconductor wafer, but at the same time reducing the formation of numerous water or cleaning fluid droplets which may cause contamination to deposit on the wafer surface. Such deposits as often occurs today reduce the yield of acceptable wafers and increase the cost of manufacturing semiconductor wafers.
SUMMARY
[0010] Broadly speaking, the present invention fills these needs by providing a cleaning and drying apparatus that is capable of removing fluids from wafer surfaces quickly while at the same time reducing wafer contamination. It should be appreciated that the present invention can be implemented in numerous ways, including as a process, an apparatus, a system, a device or a method. Several inventive embodiments of the present invention are described below.
[0011] In one embodiment, a substrate preparation apparatus is disclosed. The apparatus includes a housing configured to be installed in a substrate fabrication facility. The housing includes a manifold for use in preparing a wafer surface. The manifold is configured to include a first process window in a first portion of the manifold. A first fluid meniscus is capable of being defined within the first process window. Further included is a second process window in a second portion of the manifold. A second fluid meniscus is capable of being defined within the second process window. An arm is integrated with the housing, and the arm is coupled to the manifold, such that the arm is capable of positioning the manifold in proximity with the substrate during operation.
[0012] In one embodiment, a method for processing a substrate is provided which includes generating a fluid meniscus on the surface of the vertically oriented substrate, and moving the fluid meniscus over the surface of the vertically oriented substrate to process the surface of the substrate.
[0013] In another embodiment, a substrate preparation apparatus to be used in substrate processing operation is provided which includes arm capable of vertical movement between a first edge of the substrate to a second edge of the substrate. The apparatus further includes a head coupled to the arm, the head being capable of forming a fluid meniscus on a surface of the substrate and capable of being moved over the surface of the substrate.
[0014] In yet another embodiment, a manifold for use in preparing a wafer surface is provided. The manifold includes a first process window in a first portion of the manifold being configured generate a first fluid meniscus on the wafer surface. The manifold further includes a second process window in a second portion of the manifold being configured to generate a second fluid meniscus on the wafer surface.
[0015] The advantages of the present invention are numerous. Most notably, the apparatuses and methods described herein efficiently dry and clean a semiconductor wafer while reducing fluids and contaminants remaining on a wafer surface. Consequently, wafer processing and production may be increased and higher wafer yields may be achieved due to efficient wafer drying with lower levels of contamination. The present invention enables the improved drying and cleaning through the use of vacuum fluid removal in conjunction with fluid input. The pressures generated on a fluid film at the wafer surface by the aforementioned forces enable optimal removal of fluid at the wafer surface with a significant reduction in remaining contamination as compared with other cleaning and drying techniques. In addition, the present invention may utilize application of an isopropyl alcohol (IPA) vapor and deionized water towards a wafer surface along with generation of a vacuum near the wafer surface at substantially the same time. This enables both the generation and intelligent control of a meniscus and the reduction of water surface tension along a deionized water interface and therefore enables optimal removal of fluids from the wafer surface without leaving contaminants. The meniscus generated by input of IPA, DIW and output of fluids may be moved along the surface of the wafer to clean and dry the wafer. The meniscus may be moved vertically from a top portion of the wafer to a bottom portion of the wafer. The up to down drying operation of a vertically oriented wafer reduces random water movements because in such a configuration, gravity is the main force generating water movement on the unprocessed portion of the wafer. In addition, the meniscus may be managed more effectively due to the known gravitational effects on the meniscus. Therefore, the present invention evacuates fluid from wafer surfaces with extreme effectiveness while substantially reducing contaminant formation due to ineffective drying such as for example, spin drying.
[0016] Other aspects and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings. To facilitate this description, like reference numerals designate like structural elements.
[0018] FIG. 1 illustrates movement of cleaning fluids on a wafer during an SRD drying process.
[0019] FIG. 2A shows a wafer cleaning and drying system in accordance with one embodiment of the present invention.
[0020] FIG. 2B shows an alternate view of the wafer cleaning and drying system in accordance with one embodiment of present invention.
[0021] FIG. 2C illustrates a side close-up view of the wafer cleaning and drying system holding a wafer in accordance with one embodiment of the present invention.
[0022] FIG. 2D shows another side close-up view of the wafer cleaning and drying system in accordance with one embodiment of the present invention.
[0023] FIG. 3A shows a top view illustrating the wafer cleaning and drying system with dual proximity heads in accordance with one embodiment of the present invention.
[0024] FIG. 3B illustrates a side view of the wafer cleaning and drying system with dual proximity heads in accordance with one embodiment of the present invention.
[0025] FIG. 4A shows a top view of a wafer cleaning and drying system which includes multiple proximity heads for a particular surface of the wafer in accordance with one embodiment of the present invention.
[0026] FIG. 4B shows a side view of the wafer cleaning and drying system which includes multiple proximity heads for a particular surface of the wafer in accordance with one embodiment of the present invention.
[0027] FIG. 5A shows a top view of a wafer cleaning and drying system with a proximity head in a horizontal configuration which extends across a diameter of the wafer 108 in accordance with one embodiment of the present invention.
[0028] FIG. 5B shows a side view of a wafer cleaning and drying system with the proximity heads in a horizontal configuration which extends across a diameter of the wafer in accordance with one embodiment of the present invention.
[0029] FIG. 5C shows a top view of a wafer cleaning and drying system with the proximity heads in a horizontal configuration which is configured to clean and/or dry the wafer that is stationary in accordance with one embodiment of the present invention.
[0030] FIG. 5D shows a side view of a wafer cleaning and drying system with the proximity heads in a horizontal configuration which is configured to clean and/or dry the wafer that is stationary in accordance with one embodiment of the present invention.
[0031] FIG. 5E shows a side view of a wafer cleaning and drying system with the proximity heads in a vertical configuration enabled to clean and/or dry the wafer that is stationary in accordance with one embodiment of the present invention.
[0032] FIG. 5F shows an alternate side view of a wafer cleaning and drying system that is shifted 90 degrees from the side view shown in FIG. 5E in accordance with one embodiment of the present invention.
[0033] FIG. 5G shows a top view of a wafer cleaning and drying system with a proximity head in a horizontal configuration which extends across a radius of the wafer in accordance with one embodiment of the present invention.
[0034] FIG. 5H shows a side view of a wafer cleaning and drying system with the proximity heads and in a horizontal configuration which extends across a radius of the wafer in accordance with one embodiment of the present invention.
[0035] FIG. 6A shows a proximity head inlet/outlet orientation that may be utilized to clean and dry the wafer in accordance with one embodiment of the present invention.
[0036] FIG. 6B shows another proximity head inlet/outlet orientation that may be utilized to clean and dry the wafer in accordance with one embodiment of the present invention.
[0037] FIG. 6C shows a further proximity head inlet/outlet orientation that may be utilized to clean and dry the wafer in accordance with one embodiment of the present invention.
[0038] FIG. 6D illustrates a preferable embodiment of a wafer drying process that may be conducted by a proximity head in accordance with one embodiment of the present invention.
[0039] FIG. 6E shows another wafer drying process using another source inlet/outlet orientation that may be conducted by a proximity head in accordance with one embodiment of the present invention.
[0040] FIG. 6F shows another source inlet and outlet orientation where an additional source outlet may be utilized to input an additional fluid in accordance with one embodiment of the present invention.
[0041] FIG. 7A illustrates a proximity head performing a drying operation in accordance with one embodiment of the present invention.
[0042] FIG. 7B shows a top view of a portion of a proximity head in accordance with one embodiment of the present invention.
[0043] FIG. 7C illustrates a proximity head with angled source inlets performing a drying operation in accordance with one embodiment of the present invention.
[0044] FIG. 7D illustrates a proximity head with angled source inlets and angled source outlets performing a drying operation in accordance with one embodiment of the present invention.
[0045] FIG. 8A illustrates a side view of the proximity heads for use in a dual wafer surface cleaning and drying system in accordance with one embodiment of the present invention.
[0046] FIG. 8B shows the proximity heads in a dual wafer surface cleaning and drying system in accordance with one embodiment of the present invention.
[0047] FIG. 9A illustrates a processing window in accordance with one embodiment of the present invention.
[0048] FIG. 9B illustrates a substantially circular processing window in accordance with one embodiment of the present invention.
[0049] FIG. 9D illustrates a processing window in accordance with one embodiment of the present invention.
[0050] FIG. 9C illustrates a processing window in accordance with one embodiment of the present invention.
[0051] FIG. 10A shows an exemplary process window with the plurality of source inlets and as well as the plurality of source outlets in accordance with one embodiment of the present invention.
[0052] FIG. 10B shows processing regions of a proximity head in accordance with one embodiment of the present invention.
[0053] FIG. 11A shows a top view of a proximity head with a substantially rectangular shape in accordance with one embodiment of the present invention.
[0054] FIG. 11B illustrates a side view of the proximity head in accordance with one embodiment of present invention.
[0055] FIG. 11C shows a rear view of the proximity head in accordance with one embodiment of the present invention.
[0056] FIG. 12A shows a proximity head with a partial rectangular and partial circular shape in accordance with one embodiment of the present invention.
[0057] FIG. 12B shows a side view of the proximity head with a partial rectangular and partial circular shape in accordance with one embodiment of the present invention.
[0058] FIG. 12C shows a back view of the proximity head with a partial rectangular and partial circular shape in accordance with one embodiment of the present invention.
[0059] FIG. 13A shows a rectangular proximity head in accordance with one embodiment of the present invention.
[0060] FIG. 13B shows a rear view of the proximity head in accordance with one embodiment of the present invention.
[0061] FIG. 13C illustrates a side view of the proximity head in accordance with one embodiment of present invention.
[0062] FIG. 14A shows a rectangular proximity head in accordance with one embodiment of the present invention.
[0063] FIG. 14B shows a rear view of the rectangular proximity head in accordance with one embodiment of the present invention.
[0064] FIG. 14C illustrates a side view of the rectangular proximity head in accordance with one embodiment of present invention.
[0065] FIG. 15A shows a proximity head in operation according to one embodiment of the present invention.
[0066] FIG. 15B illustrates the proximity head as described in FIG. 15A with IPA input in accordance with one embodiment of the present invention.
[0067] FIG. 15C shows the proximity head as described in FIG. 15B , but with the N 2 /IPA flow increased to 24 ml/min in accordance with one embodiment of the present invention.
[0068] FIG. 15D shows the proximity head where the fluid meniscus is shown where the wafer is being rotated in accordance with one embodiment of the present invention.
[0069] FIG. 15E shows the proximity head where the fluid meniscus is shown where the wafer is being rotated faster than the rotation shown in FIG. 15D in accordance with one embodiment of the present invention.
[0070] FIG. 15F shows the proximity head where the N 2 /IPA flow has been increased as compared to the N 2 /IPA flow of FIG. 15D in accordance with one embodiment of the present invention.
[0071] FIG. 16A illustrates a proximity head beginning a wafer processing operation where the wafer is scanned vertically in accordance with one embodiment of the present invention.
[0072] FIG. 16B illustrates a wafer processing continuing from FIG. 16A where the proximity head has started scanning the wafer in accordance with one embodiment of the present invention.
[0073] FIG. 16C shows a continuation of a wafer processing operation from FIG. 16B in accordance with one embodiment of the present invention.
[0074] FIG. 16D illustrates the wafer processing operation continued from FIG. 16C in accordance with one embodiment of the present invention.
[0075] FIG. 16E shows the wafer processing operation continued from FIG. 16D in accordance with one embodiment of the present invention.
[0076] FIG. 16F shows a side view of the proximity heads situated over the top portion of the vertically positioned wafer in accordance with one embodiment of the present invention.
[0077] FIG. 16G illustrates a side view of the proximity heads during processing of dual surfaces of the wafer in accordance with one embodiment of the present invention.
[0078] FIG. 17A shows a wafer processing system where the wafer is held stationary in accordance with one embodiment of the present invention.
[0079] FIG. 17B shows a wafer processing system where the proximity head carrier may be held in place or moved in accordance with one embodiment of the present invention.
[0080] FIG. 17C shows a wafer processing system where the proximity head extends about a radius of the wafer in accordance with one embodiment of the present invention.
[0081] FIG. 17D shows a wafer processing system where the proximity head moves vertically and the wafer rotates in accordance with one embodiment of the present invention.
[0082] FIG. 18A shows a proximity head that may be utilized for vertical scanning of a wafer in accordance with one embodiment of the present invention.
[0083] FIG. 18B shows a side view of the proximity head in accordance with one embodiment of the present invention.
[0084] FIG. 18C shows an isometric view of the proximity head in accordance with one embodiment of the present invention.
[0085] FIG. 19A shows a multi-process window proximity head in accordance with one embodiment of the present invention.
[0086] FIG. 19B shows a multi-process window proximity head with three process windows in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
[0087] An invention for methods and apparatuses for cleaning and/or drying a wafer is disclosed. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be understood, however, by one of ordinary skill in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention.
[0088] While this invention has been described in terms of several preferred embodiments, it will be appreciated that those skilled in the art upon reading the preceding specifications and studying the drawings will realize various alterations, additions, permutations and equivalents thereof. It is therefore intended that the present invention includes all such alterations, additions, permutations, and equivalents as fall within the true spirit and scope of the invention.
[0089] FIGS. 2A through 2D below illustrate embodiments of an exemplary wafer processing system. It should be appreciated that the system is exemplary, and that any other suitable type of configuration that would enable movement of the proximity head(s) into close proximity to the wafer may be utilized. In the. embodiments shown, the proximity head(s) may move in a linear fashion from a center portion of the wafer to the edge of the wafer. It should be appreciated that other embodiments may be utilized where the proximity head(s) move in a linear fashion from one edge of the wafer to another diametrically opposite edge of the wafer, or other non-linear movements may be utilized such as, for example, in a radial motion, in a circular motion, in a spiral motion, in a zig-zag motion, etc. The motion may also be any suitable specified motion profile as desired by a user. In addition, in one embodiment, the wafer may be rotated and the proximity head moved in a linear fashion so the proximity head may process all portions of the wafer. It should also be understood that other embodiments may be utilized where the wafer is not rotated but the proximity head is configured to move over the wafer in a fashion that enables processing of all portions of the wafer. In addition, the proximity head and the wafer cleaning and drying system described herein may be utilized to clean and dry any shape and size of substrates such as for example, 200 mm wafers, 300 mm wafers, flat panels, etc. The wafer cleaning and drying system may be utilized for either or both cleaning and drying the wafer depending on the configuration of the system.
[0090] FIG. 2A shows a wafer cleaning and drying system 100 in accordance with one embodiment of the present invention. The system 100 includes rollers 102 a , 102 b , and 102 c which may hold and rotate a wafer to enable wafer surfaces to be dried. The system 100 also includes proximity heads 106 a and 106 b that, in one embodiment, are attached to an upper arm 104 a and to a lower arm 104 b respectively. The upper arm 104 a and the lower arm 104 b are part of a proximity head carrier assembly 104 which enables substantially linear movement of the proximity heads 106 a and 106 b along a radius of the wafer.
[0091] In one embodiment the proximity head carrier assembly 104 is configured to hold the proximity head 106 a above the wafer and the proximity head 106 b below the wafer in close proximity to the wafer. This may be accomplished by having the upper arm 104 a and the lower arm 104 b be movable in a vertical manner so once the proximity heads are moved horizontally into a location to start wafer processing, the proximity heads 106 a and 106 b can be moved vertically to a position in close proximity to the wafer. The upper arm 104 a and the lower arm 104 b may be configured in any suitable way so the proximity heads 106 a and 106 b can be moved to enable wafer processing as described herein. It should be appreciated that the system 100 may be configured in any suitable manner as long as the proximity head(s) may be moved in close proximity to the wafer to generate and control a meniscus as discussed below in reference to FIGS. 6D through 8B . It should also be understood that close proximity may be any suitable distance from the wafer as long as a meniscus as discussed in further reference to FIG. 6D through 8B may be maintained. In one embodiment, the proximity heads 106 a and 106 b (as well as any other proximity head described herein) may each be moved to between about 0.1 mm to about 10 mm from the wafer to initiate wafer processing operations. In a preferable embodiment, the proximity heads 106 a and 106 b (as well as any other proximity head described herein) may each be moved to between about 0.5 mm to about 4.5 mm from the wafer to initiate wafer processing operations, and in more preferable embodiment, the proximity heads 106 a and 106 b (as well as any other proximity head described herein) may be moved to about 2 mm from the wafer to initiate wafer processing operations.
[0092] FIG. 2B shows an alternate view of the wafer cleaning and drying system 100 in accordance with one embodiment of present invention. The system 100 , in one embodiment, has the proximity head carrier assembly 104 that is configured to enable the proximity heads 106 a and 106 b to be moved from the center of the wafer towards the edge of the wafer. It should be appreciated that the proximity head carrier assembly 104 may be movable in any suitable manner that would enable movement of the proximity heads 106 a and 106 b to clean and/or dry the wafer as desired. In one embodiment, the proximity head carrier assembly 104 can be motorized to move the proximity head 106 a and 106 b from the center of the wafer to the edge of the wafer. It should be understood that although the wafer cleaning and drying system 100 is shown with the proximity heads 106 a and 106 b , that any suitable number of proximity heads may be utilized such as, for example, 1, 2, 3, 4, 5, 6, etc. The proximity heads 106 a and/or 106 b of the wafer cleaning and drying system 100 may also be any suitable size or shape as shown by, for example, any of the proximity heads as described herein. The different configurations described herein generate a fluid meniscus between the proximity head and the wafer. The fluid meniscus may be moved across the wafer to clean and dry the wafer by applying fluid to the wafer surface and removing the fluids from the surface. Therefore, the proximity heads 106 a and 106 b can have any numerous types of configurations as shown herein or other configurations that enable the processes described herein. It should also be appreciated that the system 100 may clean and dry one surface of the wafer or both the top surface and the bottom surface of the wafer.
[0093] In addition, besides cleaning or drying both the top and bottom surfaces and of the wafer, the system 100 may also be configured to clean one side of the wafer and dry another side of the wafer if desired by inputting and outputting different types of fluids. It should be appreciated that the system 100 may utilize the application of different chemicals top and bottom in the proximity heads 106 a and 106 b respectively depending on the operation desired. The proximity heads can be configured to clean and dry the bevel edge of the wafer in addition to cleaning and/or drying the top and/or bottom of the wafer. This can be accomplished by moving the meniscus off the edge the wafer which cleans the bevel edge. It should also be understood that the proximity heads 106 a and 106 b may be the same type of apparatus or different types of proximity heads.
[0094] FIG. 2C illustrates a side close-up view of the wafer cleaning and drying system 100 holding a wafer 108 in accordance with one embodiment of the present invention. The wafer 108 may be held and rotated by the rollers 102 a , 102 b , and 102 c in any suitable orientation as long as the orientation enables a desired proximity head to be in close proximity to a portion of the wafer 108 that is to be cleaned or dried. In one embodiment, the roller 102 b may be rotated by using a spindle 111 , and the roller 102 c may held and rotated by a roller arm 109 . The roller 102 a may also be rotated by its own spindle (as shown in FIG. 3B . In one embodiment, the rollers 102 a , 102 b , and 102 c can rotate in a clockwise direction to rotate the wafer 108 in a counterclockwise direction. It should be understood that the rollers may be rotated in either a clockwise or a counterclockwise direction depending on the wafer rotation desired. In one embodiment, the rotation imparted on the wafer 108 by the rollers 102 a , 102 b , and 102 c serves to move a wafer area that has not been processed into close proximity to the proximity heads 106 a and 106 b . However, the rotation itself does not dry the wafer or move fluid on the wafer surfaces towards the edge of the wafer. Therefore, in an exemplary drying operation, the wet areas of the wafer would be presented to the proximity heads 106 a and 106 b through both the linear motion of the proximity heads 106 a and 106 b and through the rotation of the wafer 108 . The drying or cleaning operation itself is conducted by at least one of the proximity heads. Consequently, in one embodiment, a dry area of the wafer 108 would expand from a center region to the edge region of the wafer 108 in a spiral movement as a drying operation progresses. In a preferable embodiment, the dry are of the wafer 108 would move around the wafer 108 and the wafer 108 would be dry in one rotation (if the length of the proximity heads 106 a and 106 b are at least a radius of the wafer 108 ) By changing the configuration of the system 100 and the orientation of and movement of the proximity head 106 a and/or the proximity head 106 b , the drying movement may be changed to accommodate nearly any suitable type of drying path.
[0095] It should be understood that the proximity heads 106 a and 106 b may be configured to have at least one of first source inlet configured to input deionized water (DIW) (also known as a DIW inlet), at least one of a second source inlet configured to input N 2 carrier gas containing isopropyl alcohol (IPA) in vapor form (also known as IPA inlet), and at least one source outlet configured to output fluids from a region between the wafer and a particular proximity head by applying vacuum (also known as vacuum outlet). It should be appreciated that the vacuum utilized herein may also be suction. In addition, other types of solutions may be inputted into the first source inlet and the second source inlet such as, for example, cleaning solutions, ammonia, HF, etc. It should be appreciated that although IPA vapor is used in some of the exemplary embodiments, any other type of vapor may be utilized such as for example, nitrogen, any suitable alcohol vapor, organic compounds, etc. that may be miscible with water.
[0096] In one embodiment, the at least one N 2 /IPA vapor inlet is adjacent to the at least one vacuum outlet which is in turn adjacent to the at least one DIW inlet to form an IPA-vacuum-DIW orientation. It should be appreciated that other types of orientations such as IPA-DIW-vacuum, DIW-vacuum-IPA, vacuum-IPA-DIW, etc. may be utilized depending on the wafer processes desired and what type of wafer cleaning and drying mechanism is sought to be enhanced. In a preferable embodiment, the IPA-vacuum-DIW orientation may be utilized to intelligently and powerfully generate, control, and move the meniscus located between a proximity head and a wafer to clean and dry wafers. The DIW inlets, the N 2 /IPA vapor inlets, and the vacuum outlets may be arranged in any suitable manner if the above orientation is maintained. For example, in addition to the N 2 /IPA vapor inlet, the vacuum outlet, and the DIW inlet, in an additional embodiment, there may be additional sets of IPA vapor outlets, DIW inlets and/or vacuum outlets depending on the configuration of the proximity head desired. Therefore, another embodiment may utilize an IPA-vacuum-DIW-DIW-vacuum-IPA or other exemplary embodiments with an IPA source inlet, vacuum source outlet, and DIW source inlet configurations are described herein with a preferable embodiment being described in reference to FIG. 6D . It should be appreciated that the exact configuration of the IPA-vacuum-DIW orientation may be varied depending on the application. For example, the distance between the IPA input, vacuum, and DIW input locations may be varied so the distances are consistent or so the distances are inconsistent. In addition, the distances between the IPA input, vacuum, and DIW output may differ in magnitude depending on the size, shape, and configuration of the proximity head 106 a and the desired size of a process window (i.e., meniscus shape and size) as described in further detail in reference to FIG. 10 . In addition, as discussed in reference to FIG. 10 , the IPA-vacuum-DIW orientation is configured so a vacuum region substantially surrounds a DIW region and the IPA region substantially surrounds at least the trailing edge region of the vacuum region.
[0097] FIG. 2D shows another side close-up view of the wafer cleaning and drying system 100 in accordance with one embodiment of the present invention. In this embodiment, the proximity heads 106 a and 106 b have been positioned in close proximity to a top surface 108 a and a bottom surface 108 b of the wafer 108 respectively by utilization of the proximity head carrier assembly 104 . Once in this position, the proximity heads 106 a and 106 b may utilize the IPA and DIW source inlets and a vacuum source outlet(s) to generate wafer processing meniscuses in contact with the wafer 108 which are capable of removing fluids from a top surface 108 a and a bottom surface 108 b . The wafer processing meniscus may be generated in accordance with the descriptions in reference to FIGS. 6 through 9 B where IPA vapor and DIW are inputted into the region between the wafer 108 and the proximity heads 106 a and 106 b . At substantially the same time the IPA and DIW is inputted, a vacuum may be applied in close proximity to the wafer surface to output the IPA vapor, the DIW, and the fluids that may be on a wafer surface. It should be appreciated that although IPA is utilized in the exemplary embodiment, any other suitable type of vapor may be utilized such as for example, nitrogen, any suitable alcohol vapor, organic compounds, hexanol, ethyl glycol, etc. that may be miscible with water. These fluids may also be known as surface tension reducing fluids. The portion of the DIW that is in the region between the proximity head and the wafer is the meniscus. It should be appreciated that as used herein, the term “output” can refer to the removal of fluid from a region between the wafer 108 and a particular proximity head, and the term “input” can be the introduction of fluid to the region between the wafer 108 and the particular proximity head.
[0098] In another exemplary embodiment, the proximity heads 106 a and 106 b may be moved in a manner so all parts of the wafer 108 are cleaned, dried, or both without the wafer 108 being rotated. In such an embodiment, the proximity head carrier assembly 104 may be configured to enable movement of the either one or both of the proximity heads 106 a and 106 b to close proximity of any suitable region of the wafer 108 . In one embodiment, of the proximity heads are smaller in length than a radius of the wafer, the proximity heads may be configured to move in a spiral manner from the center to the edge of the wafer 108 or vice versa. In a preferable embodiment, when the proximity heads are larger in length than a radius of the wafer, the proximity heads 106 a and 106 b may be moved over the entire surface of the wafer in one rotation. In another embodiment, the proximity heads 104 a and 104 b may be configured to move in a linear fashion back and forth across the wafer 108 so all parts of the wafer surfaces 108 a and/or 108 b may be processed. In yet another embodiment, configurations as discussed below in reference to FIG. 5C through 5H may be utilized. Consequently, countless different configurations of the system 100 may be utilized in order to obtain an optimization of the wafer processing operation.
[0099] FIG. 3A shows a top view illustrating the wafer cleaning and drying system 100 with dual proximity heads in accordance with one embodiment of the present invention. As described above in reference to FIGS. 2A to 2 D, the upper arm 104 a may be configured to move and hold the proximity head 106 a in a position in close proximity over the wafer 108 . The upper arm 104 a may also be configured to move the proximity head 106 a from a center portion of the wafer 108 towards the edge of the wafer 108 in a substantially linear fashion 113 . Consequently, in one embodiment, as the wafer 108 moves as shown by rotation 112 , the proximity head 106 a is capable of removing a fluid film from the top surface 108 a of the wafer 108 using a process described in further detail in reference to FIGS. 6 through 8 . Therefore, the proximity head 106 a may dry the wafer 108 in a substantially spiral path over the wafer 108 . In another embodiment as shown in reference to FIG. 3B , there may be a second proximity head located below the wafer 108 to remove a fluid film from the bottom surface 108 b of the wafer 108 .
[0100] FIG. 3B illustrates a side view of the wafer cleaning and drying system 100 with dual proximity heads in accordance with one embodiment of the present invention. In this embodiment, the system 100 includes both the proximity head 106 a capable of processing a top surface of the wafer 108 and the proximity head 106 b capable of processing a bottom surface of the wafer 108 . In one embodiment, spindles lIla and 111 b along with a roller arm 109 may rotate the rollers 102 a , 102 b , and 102 c respectively. This rotation of the rollers 102 a , 102 b , and 102 c may rotate the wafer 108 so substantially all surfaces of the wafer 108 may be presented to the proximity heads 106 a and 106 b for drying and/or cleaning. In one embodiment, while the wafer 108 is being rotated, the proximity heads 106 a and 106 b are brought to close proximity of the wafer surfaces 108 a and 108 b by the arms 104 a and 104 b respectively. Once the proximity heads 106 a and 106 b are brought into close proximity to the wafer 108 , the wafer drying or cleaning may be begun. In operation, the proximity heads 106 a and 106 b may each remove fluids from the wafer 108 by applying IPA, deionized water and vacuum to the top surface and the bottom surface of the wafer 108 as described in reference to FIG. 6 .
[0101] In one embodiment, by using the proximity heads 106 a and 106 b , the system 100 may dry a 200 mm wafer in less than 45 seconds. In another embodiment, where the proximity heads 106 a and 106 b are at least a radius of the wafer in length, the drying time for a wafer may be less than 30 seconds. It should be understood that drying or cleaning time may be decreased by increasing the speed at which the proximity heads 106 a and 106 b travels from the center of the wafer 108 to the edge of the wafer 108 . In another embodiment, the proximity heads 106 a and 106 b may be utilized with a faster wafer rotation to dry the wafer 108 in less time. In yet another embodiment, the rotation of the wafer 108 and the movement of the proximity heads 106 a and 106 b may be adjusted in conjunction to obtain an optimal drying/cleaning speed. In one embodiment, the proximity heads 106 a and 106 b may move linearly from a center region of the wafer 108 to the edge of the wafer 108 at between about 0 mm per second to about 50 mm per second.
[0102] FIG. 4A shows a top view of a wafer cleaning and drying system 100 - 1 which includes multiple proximity heads for a particular surface of the wafer 108 in accordance with one embodiment of the present invention. In this embodiment, the system 100 - 1 includes an upper arm 104 a - 1 and an upper arm 104 a - 2 . As shown in FIG. 4B , the system 100 - 1 also may include lower arm 104 b - 1 and lower arm 104 b - 2 connected to proximity heads 106 b - 1 and 106 b - 2 respectively. In the system 100 - 1 , the proximity heads 106 a - 1 and 106 a - 2 (as well as 106 b - 1 and 106 b - 2 if top and bottom surface processing is being conducted) work in conjunction so, by having two proximity heads processing a particular surface of the wafer 108 , drying time or cleaning time may be cut to about half of the time. Therefore, in operation, while the wafer 108 is rotated, the proximity heads 106 a - 1 , 106 a - 2 , 106 b - 1 , and 106 b - 2 start processing the wafer 108 near the center of the wafer 108 and move outward toward the edge of the wafer 108 in a substantially linear fashion. In this way, as the rotation 112 of the wafer 108 brings all regions of the wafer 108 in proximity with the proximity heads so as to process all parts of the wafer 108 . Therefore, with the linear movement of the proximity heads 106 a - 1 , 106 a - 2 , 106 b - 1 , and 106 b - 2 and the rotational movement of the wafer 108 , the wafer surface being dried moves in a spiral fashion from the center of the wafer 108 to the edge of the wafer 108 .
[0103] In another embodiment, the proximity heads 106 a - 1 and 106 b - 1 may start processing the wafer 108 and after they have moved away from the center region of the wafer 108 , the proximity heads 106 a - 2 and 106 b - 2 may be moved into place in the center region of the wafer 108 to augment in wafer processing operations. Therefore, the wafer processing time may be decreased significantly by using multiple proximity heads to process a particular wafer surface.
[0104] FIG. 4B shows a side view of the wafer cleaning and drying system 100 - 1 which includes multiple proximity heads for a particular surface of the wafer 108 in accordance with one embodiment of the present invention. In this embodiment, the system 100 - 1 includes both the proximity heads 106 a - 1 and 106 a - 2 that are capable of processing the top surface 108 a of the wafer 108 , and proximity heads 106 b - 1 and 106 b - 2 capable of processing the bottom surface 108 b of the wafer 108 . As in the system 100 , the spindles 111 a and 111 b along with a roller arm 109 may rotate the rollers 102 a , 102 b , and 102 c respectively. This rotation of the rollers 102 a , 102 b , and 102 c may rotate the wafer 108 so substantially all surfaces of the wafer 108 may brought in close proximity to the proximity heads 106 a - 1 , 106 a - 2 , 106 b - 1 , and 106 b - 2 for wafer processing operations.
[0105] In operation, each of the proximity heads 106 a - 1 , 106 a - 2 , 106 b - 1 , and 106 b - 2 may remove fluids from the wafer 108 by applying IPA, deionized water and vacuum to the top surface and the bottom surface of the wafer 108 as shown, for example, in FIG. 6 through 8 . By having two proximity heads per wafer side, the wafer processing operation (i.e., cleaning and/or drying) may be accomplished in substantially less time. It should be appreciated that as with the wafer processing system described in reference to FIG. 3A and 3B , the speed of the wafer rotation may be varied to any suitable speed as long as the configuration enables proper wafer processing. In one embodiment, the wafer processing time may be decreased when half a rotation of the wafer 108 is used to dry the entire wafer. In such an embodiment, the wafer processing speed may be about half of the processing speed when only one proximity head is utilized per wafer side.
[0106] FIG. 5A shows a top view of a wafer cleaning and drying system 100 - 2 with a proximity head 106 a - 3 in a horizontal configuration which extends across a diameter of the wafer 108 in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 a - 3 is held by an upper arm 104 a - 3 that extends across a diameter of the wafer 108 . In this embodiment, the proximity head 106 a - 3 may be moved into a cleaning/drying position by a vertical movement of the upper arm 104 a - 3 so the proximity head 106 a - 3 can be in a position that is in close proximity to the wafer 108 . Once the proximity head 106 a - 3 is in close proximity to the wafer 108 , the wafer processing operation of a top surface of the wafer 108 can take place.
[0107] FIG. 5B shows a side view of a wafer cleaning and drying system 100 - 2 with the proximity heads 106 a - 3 and 106 b - 3 in a horizontal configuration which extends across a diameter of the wafer 108 in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 a - 3 and the proximity head 106 b - 3 both are elongated to be able to span the diameter of the wafer 108 . In one embodiment, while the wafer 108 is being rotated, the proximity heads 106 a - 3 and 106 b - 3 are brought to close proximity of the wafer surfaces 108 a and 108 b by the top arm 104 a and a bottom arm 106 b - 3 respectively. Because the proximity heads 106 a - 3 and 106 b - 3 extend across the wafer 108 , only half of a full rotation may be needed to clean/dry the wafer 108 .
[0108] FIG. 5C shows a top view of a wafer cleaning and drying system 100 - 3 with the proximity heads 106 a - 3 and 106 b - 3 in a horizontal configuration which is configured to clean and/or dry the wafer 108 that is stationary in accordance with one embodiment of the present invention. In this embodiment, the wafer 108 may be held stationary by any suitable type of wafer holding device such as, for example, an edge grip, fingers with edge attachments, etc. The proximity head carrier assembly 104 ′″ is configured to be movable from one edge of the wafer 108 across the diameter of the wafer 108 to an edge on the other side of the wafer 108 after crossing the entire wafer diameter. In this fashion, the proximity head 106 a - 3 and/or the proximity head 106 b - 3 (as shown below in reference to FIG. 5D ) may move across the wafer following a path along a diameter of the wafer 108 from one edge to an opposite edge. It should be appreciated that the proximity heads 106 a - 3 and/or 106 b - 3 may be move from any suitable manner that would enable moving from one edge of the wafer 108 to another diametrically opposite edge. In one embodiment, the proximity head 106 a - 3 and/or the proximity head 106 b - 3 may move in directions 121 (e.g., top to bottom or bottom to top of FIG. 5C ). Therefore, the wafer 108 may stay stationary without any rotation or movement and the proximity heads 106 a - 3 and/or the proximity head 106 b - 3 may move into close proximity of the wafer and, through one pass over the wafer 108 , clean/dry the top and/or bottom surface of the wafer 108 .
[0109] FIG. 5D shows a side view of a wafer cleaning and drying system 100 - 3 with the proximity heads 106 a - 3 and 106 b - 3 in a horizontal configuration which is configured to clean and/or dry the wafer 108 that is stationary in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 a - 3 is in a horizontal position with the wafer 108 also in a horizontal position. By use of the proximity head 106 a - 3 and the proximity head 106 b - 3 that spans at least the diameter of the wafer 108 , the wafer 108 may be cleaned and/or dried in one pass by moving proximity heads 106 a - 3 and 106 b - 3 in the direction 121 as discussed in reference to FIG. 5C .
[0110] FIG. 5E shows a side view of a wafer cleaning and drying system 100 - 4 with the proximity heads 106 a - 3 and 106 b - 3 in a vertical configuration enabled to clean and/or dry the wafer 108 that is stationary in accordance with one embodiment of the present invention. In this embodiment, the proximity heads 106 a - 3 and 106 b - 3 are in a vertical configuration, and the proximity heads 106 a - 3 and 106 b - 3 are configured to move either from left to right, or from right to left, beginning from a first edge of the wafer 108 to a second edge of the wafer 108 that is diametrically opposite to the first edge. Therefore, in such as embodiment, the proximity head carrier assembly 104 ′″ may move the proximity heads 104 a - 3 and 104 b - 3 in close proximity with the wafer 108 and also enable the movement of the proximity heads 104 a - 3 and 104 b - 3 across the wafer from one edge to another so the wafer 108 may be processed in one pass thereby decreasing the time to clean and/or dry the wafer 108 .
[0111] FIG. 5F shows an alternate side view of a wafer cleaning and drying system 100 - 4 that is shifted 90 degrees from the side view shown in FIG. 5E in accordance with one embodiment of the present invention. It should be appreciated that the proximity head carrier assembly 104 ′″ may be oriented in any suitable manner such as for example, having the proximity head carrier assembly 104 ′″ rotated 180 degrees as compared with what is shown in FIG. 5F .
[0112] FIG. 5G shows a top view of a wafer cleaning and drying system 100 - 5 with a proximity head 106 a - 4 in a horizontal configuration which extends across a radius of the wafer 108 in accordance with one embodiment of the present invention. In one embodiment, the proximity head 106 a - 4 extends across less than a radius of a substrate being processed. In another embodiment, the proximity head 106 a - 4 may extend the radius of the substrate being processed. In a preferable embodiment, the proximity head 106 a - 4 extends over a radius of the wafer 108 so the proximity head may process both the center point of the wafer 108 as well as an edge of the wafer 108 so the proximity head 106 a - 4 can cover and process the center point of the wafer and the edge of the wafer. In this embodiment, the proximity head 106 a - 4 may be moved into a cleaning/drying position by a vertical movement of the upper arm 104 a - 4 so the proximity head 106 a - 4 can be in a position that is in close proximity to the wafer 108 . Once the proximity head 106 a - 4 is in close proximity to the wafer 108 , the wafer processing operation of a top surface of the wafer 108 can take place. Because, in one embodiment, the proximity head 106 a - 4 extends over the radius of the wafer, the wafer may be cleaned and/or dried in one rotation.
[0113] FIG. 5H shows a side view of a wafer cleaning and drying system 100 - 5 with the proximity heads 106 a - 4 and 106 b - 4 in a horizontal configuration which extends across a radius of the wafer 108 in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 a - 4 and the proximity head 106 b - 4 both are elongated to be able to extend over and beyond the radius of the wafer 108 . As discussed in reference to FIG. 5G , depending on the embodiment desired, the proximity head 106 a - 4 may extend less than a radius, exactly a radius, or greater than a radius of the wafer 108 . In one embodiment, while the wafer 108 is being rotated, the proximity heads 106 a - 4 and 106 b - 4 are brought to close proximity of the wafer surfaces 108 a and 108 b by the top arm 104 a and a bottom arm 106 b - 4 respectively. Because in one embodiment, the proximity heads 106 a - 4 and 106 b - 4 extend across greater than the radius of the wafer 108 , only a full rotation may be needed to clean/dry the wafer 108 .
[0114] FIG. 6A shows a proximity head inlet/outlet orientation 117 that may be utilized to clean and dry the wafer 108 in accordance with one embodiment of the present invention. In one embodiment, the orientation 117 is a portion of a proximity head 106 a where other source inlets 302 and 306 in addition to other source outlets 304 may be utilized in addition to the orientation 117 shown. The orientation 117 may include a source inlet 306 on a leading edge 109 with a source outlet 304 in between the source inlet 306 and the source outlet 302 .
[0115] FIG. 6B shows another proximity head inlet/outlet orientation 119 that may be utilized to clean and dry the wafer 108 in accordance with one embodiment of the present invention. In one embodiment, the orientation 119 is a portion of a proximity head 106 a where other source inlets 302 and 306 in addition to other source outlets 304 may be utilized in addition to the orientation 119 shown. The orientation 119 may include a source outlet 304 on a leading edge 109 with a source inlet 302 in between the source outlet 304 and the source inlet 306 .
[0116] FIG. 6C shows a further proximity head inlet/outlet orientation 121 that may be utilized to clean and dry the wafer 108 in accordance with one embodiment of the present invention. In one embodiment, the orientation 121 is a portion of a proximity head 106 a where other source inlets 302 and 306 in addition to other source outlets 304 may be utilized in addition to the orientation 119 shown. The orientation 119 may include a source inlet 306 on a leading edge 109 with a source inlet 302 in between the source outlet 304 and the source outlet 306 .
[0117] FIG. 6D illustrates a preferable embodiment of a wafer drying process that may be conducted by a proximity head 106 a in accordance with one embodiment of the present invention. Although FIG. 6 shows a top surface 108 a being dried, it should be appreciated that the wafer drying process may be accomplished in substantially the same way for the bottom surface 108 b of the wafer 108 . In one embodiment, a source inlet 302 may be utilized to apply isopropyl alcohol (IPA) vapor toward a top surface 108 a of the wafer 108 , and a source inlet 306 may be utilized to apply deionized water (DIW) toward the top surface 108 a of the wafer 108 . In addition, a source outlet 304 may be utilized to apply vacuum to a region in close proximity to the wafer surface to remove fluid or vapor that may located on or near the top surface 108 a . It should be appreciated that any suitable combination of source inlets and source outlets may be utilized as long as at least one combination exists where at least one of the source inlet 302 is adjacent to at least one of the source outlet 304 which is in turn adjacent to at least one of the source inlet 306 . The IPA may be in any suitable form such as, for example, IPA vapor where IPA in vapor form is inputted through use of a N 2 gas. Moreover, although DIW is utilized herein, any other suitable fluid may be utilized that may enable or enhance the wafer processing such as, for example, water purified in other ways, cleaning fluids, etc. In one embodiment, an IPA inflow 310 is provided through the source inlet 302 , a vacuum 312 may be applied through the source outlet 304 and DIW inflow 314 may be provided through the source inlet 306 . Therefore, an embodiment of the IPA-vacuum-DIW orientation as described above in reference to FIG. 2 is utilized. Consequently, if a fluid film resides on the wafer 108 , a first fluid pressure may be applied to the wafer surface by the IPA inflow 310 , a second fluid pressure may be applied to the wafer surface by the DIW inflow 314 , and a third fluid pressure may be applied by the vacuum 312 to remove the DIW, IPA and the fluid film on the wafer surface.
[0118] Therefore, in one embodiment, as the DIW inflow 314 and the IPA inflow 310 is applied toward a wafer surface, any fluid on the wafer surface is intermixed with the DIW inflow 314 . At this time, the DIW inflow 314 that is applied toward the wafer surface encounters the IPA inflow 310 . The IPA forms an interface 118 (also known as an IPA/DIW interface 118 ) with the DIW inflow 314 and along with the vacuum 312 assists in the removal of the DIW inflow 314 along with any other fluid from the surface of the wafer 108 . In one embodiment, the IPA/DIW interface 118 reduces the surface of tension of the DIW. In operation, the DIW is applied toward the wafer surface and almost immediately removed along with fluid on the wafer surface by the vacuum applied by the source outlet 304 . The DIW that is applied toward the wafer surface and for a moment resides in the region between a proximity head and the wafer surface along with any fluid on the wafer surface forms a meniscus 116 where the borders of the meniscus 116 are the IPA/DIW interfaces 118 . Therefore, the meniscus 116 is a constant flow of fluid being applied toward the surface and being removed at substantially the same time with any fluid on the wafer surface. The nearly immediate removal of the DIW from the wafer surface prevents the formation of fluid droplets on the region of the wafer surface being dried thereby reducing the possibility of contamination drying on the wafer 108 . The pressure (which is caused by the flow rate of the IPA) of the downward injection of IPA also helps contain the meniscus 116 .
[0119] The flow rate of the N 2 carrier gas containing the IPA may assist in causing a shift or a push of water flow out of the region between the proximity head and the wafer surface and into the source outlets 304 (suction outlets) through which the fluids may be outputted from the proximity head. It is noted that the push of wafer flow is not a process requirement but can be used to optimize meniscus boundary control. Therefore, as the IPA and the DIW is pulled into the source outlets 304 , the boundary making up the IPA/DIW interface 118 is not a continuous boundary because gas (e.g., air) is being pulled into the source outlets 304 along with the fluids. In one embodiment, as the vacuum from the source outlet 304 pulls the DIW, IPA, and the fluid on the wafer surface, the flow into the source outlet 304 is discontinuous. This flow discontinuity is analogous to fluid and gas being pulled up through a straw when a vacuum is exerted on combination of fluid and gas. Consequently, as the proximity head 106 a moves, the meniscus moves along with the proximity head, and the region previously occupied by the meniscus has been dried due to the movement of the IPA/DIW interface 118 . It should also be understood that the any suitable number of source inlets 302 , source outlets 304 and source inlets 306 may be utilized depending on the configuration of the apparatus and the meniscus size and shape desired. In another embodiment, the liquid flow rates and the vacuum flow rates are such that the total liquid flow into the vacuum outlet is continuous, so no gas flows into the vacuum outlet.
[0120] It should be appreciated any suitable flow rate may be utilized for the N 2 /IPA, DIW, and vacuum as long as the meniscus 116 can be maintained. In one embodiment, the flow rate of the DIW through a set of the source inlets 306 is between about 25 ml per minute to about 3,000 ml per minute. In a preferable embodiment, the flow rate of the DIW through the set of the source inlets 306 is about 400 ml per minute. It should be understood that the flow rate of fluids may vary depending on the size of the proximity head. In one embodiment a larger head may have a greater rate of fluid flow than smaller proximity heads. This may occur because larger proximity heads, in one embodiment, have more source inlets 302 and 306 and source outlets 304 .
[0121] In one embodiment, the flow rate of the N 2 /IPA vapor through a set of the source inlets 302 is between about 1 standard cubic feet per hour (SCFH) to about 100 SCFH. In a preferable embodiment, the IPA flow rate is between about 5 and 50 SCFH.
[0122] In one embodiment, the flow rate for the vacuum through a set of the source outlets 304 is between about 10 standard cubic feet per hour (SCFH) to about 1250 SCFH. In a preferable embodiment, the flow rate for a vacuum though the set of the source outlets 304 is about 350 SCFH. In an exemplary embodiment, a flow meter may be utilized to measure the flow rate of the N 2 /IPA, DIW, and the vacuum.
[0123] FIG. 6E shows another wafer drying process using another source inlet/outlet orientation that may be conducted by a proximity head 106 a in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 a may be moved over the top surface 108 a of the wafer 108 so the meniscus may be moved along the wafer surface 108 a . The meniscus applies fluid to the wafer surface and removes fluid from the wafer surface thereby cleaning and drying the wafer simultaneously. In this embodiment, the source inlet 306 applies a DIW flow 314 toward the wafer surface 108 a , the source inlet 302 applies IPA flow 310 toward the wafer surface 108 a , and the source outlet 312 removes fluid from the wafer surface 108 a . It should be appreciated that in this embodiment as well as other embodiments of the proximity head 106 a described herein, additional numbers and types of source inlets and source outlets may be used in conjunction with the orientation of the source inlets 302 and 306 and the source outlets 304 shown in FIG. 6E . In addition, in this embodiment as well as other proximity head embodiments, by controlling the amount of flow of fluids onto the wafer surface 108 a and by controlling the vacuum applied, the meniscus may be managed and controlled in any suitable manner. For example, in one embodiment, by increasing the DIW flow 314 and/or decreasing the vacuum 312 , the outflow through the source outlet 304 may be nearly all DIW and the fluids being removed from the wafer surface 108 a . In another embodiment, by decreasing the DIW flow 314 and/or increasing the vacuum 312 , the outflow through the source outlet 304 may be substantially a combination of DIW and air as well as fluids being removed from the wafer surface 108 a.
[0124] FIG. 6F shows another source inlet and outlet orientation where an additional source outlet 307 may be utilized to input an additional fluid in accordance with one embodiment of the present invention. The orientation of inlets and outlets as shown in FIG. 6E is the orientation described in further detail in reference to FIG. 6D except the additional source outlet 307 is included adjacent to the source inlet 306 on a side opposite that of the source outlet 304 . In such an embodiment, DIW may be inputted through the source inlet 306 while a different solution such as, for example, a cleaning solution may be inputted through the source inlet 307 . Therefore, a cleaning solution flow 315 may be utilized to enhance cleaning of the wafer 108 while at substantially the same time drying the top surface 108 a of the wafer 108 .
[0125] FIG. 7A illustrates a proximity head 106 performing a drying operation in accordance with one embodiment of the present invention. The proximity head 106 , in one embodiment, moves while in close proximity to the top surface 108 a of the wafer 108 to conduct a cleaning and/or drying operation. It should be appreciated that the proximity head 106 may also be utilized to process (e.g., clean, dry, etc.) the bottom surface 108 b of the wafer 108 . In one embodiment, the wafer 108 is rotating so the proximity head 106 may be moved in a linear fashion along the head motion while fluid is removed from the top surface 108 a . By applying the IPA 310 through the source inlet 302 , the vacuum 312 through source outlet 304 , and the deionized water 314 through the source inlet 306 , the meniscus 116 as discussed in reference to FIG. 6 may be generated.
[0126] FIG. 7B shows a top view of a portion of a proximity head 106 in accordance with one embodiment of the present invention. In the top view of one embodiment, from left to right are a set of the source inlet 302 , a set of the source outlet 304 , a set of the source inlet 306 , a set of the source outlet 304 , and a set of the source inlet 302 . Therefore, as N 2 /IPA and DIW are inputted into the region between the proximity head 106 and the wafer 108 , the vacuum removes the N 2 /IPA and the DIW along with any fluid film that may reside on the wafer 108 . The source inlets 302 , the source inlets 306 , and the source outlets 304 described herein may also be any suitable type of geometry such as for example, circular opening, triangle opening, square opening, etc. In one embodiment, the source inlets 302 and 306 and the source outlets 304 have circular openings.
[0127] FIG. 7C illustrates a proximity head 106 with angled source inlets 302 ′ performing a drying operation in accordance with one embodiment of the present invention. It should be appreciated that the source inlets 302 ′ and 306 and the source outlet(s) 304 described herein may be angled in any suitable way to optimize the wafer cleaning and/or drying process. In one embodiment, the angled source inlets 302 ′ that input IPA vapor onto the wafer 108 is angled toward the source inlets 306 such that the IPA vapor flow is directed to contain the meniscus 116 .
[0128] FIG. 7D illustrates a proximity head 106 with angled source inlets 302 ′ and angled source outlets 304 ′ performing a drying operation in accordance with one embodiment of the present invention. It should be appreciated that the source inlets 302 ′ and 306 and the angled source outlet(s) 304 ′ described herein may be angled in any suitable way to optimize the wafer cleaning and/or drying process.
[0129] In one embodiment, the angled source inlets 302 ′ that input IPA vapor onto the wafer 108 is angled at an angle θ 500 toward the source inlets 306 such that the IPA vapor flow is directed to contain the meniscus 116 . The angled source outlet 304 ′ may, in one embodiment, be angled at an angle θ 500 towards the meniscus 116 . It should be appreciated that the angle θ 500 and the angle θ 502 may be any suitable angle that would optimize the management and control of the meniscus 116 . In one embodiment, the angle θ 500 is greater than 0 degrees and less than 90 degrees , and the angle θ 502 is greater than 0 degrees and less than 90 degrees . In a preferable embodiment, the angle θ 500 is about 15 degrees, and in another preferable embodiment, the angle angled at an angle θ 502 is about 15 degrees . The angle θ 500 and the angle θ 502 adjusted in any suitable manner to optimize meniscus management. In one embodiment, the angle θ 500 and the angle θ 502 may be the same, and in another embodiment, the angle angle θ 500 and the angle θ 502 may be different. By angling the angled source inlet(s) 302 ′ and/or angling the angled source outlet(s) 304 ′, the border of the meniscus may be more clearly defined and therefore control the drying and/or cleaning the surface being processed.
[0130] FIG. 8A illustrates a side view of the proximity heads 106 and 106 b for use in a dual wafer surface cleaning and drying system in accordance with one embodiment of the present invention. In this embodiment, by usage of source inlets 302 and 306 to input N 2 /IPA and DIW respectively along with the source outlet 304 to provide a vacuum, the meniscus 116 may be generated. In addition, on the side of the source inlet 306 opposite that of the source inlet 302 , there may be a source outlet 304 to remove DIW and to keep the meniscus 116 intact. As discussed above, in one embodiment, the source inlets 302 and 306 may be utilized for IPA inflow 310 and DIW inflow 314 respectively while the source outlet 304 may be utilized to apply vacuum 312 . It should be appreciated that any suitable configuration of source inlets 302 , source outlets 304 and source inlets 306 may be utilized. For example, the proximity heads 106 and 106 b may have a configuration of source inlets and source outlets like the configuration described above in reference to FIG. 7A and 7B . In addition, in yet more embodiments, the proximity heads 106 and 106 b may be of a configuration as shown below in reference to FIGS. 9 through 15 . Any suitable surface coming into contact with the meniscus 116 may be dried by the movement of the meniscus 116 into and away from the surface.
[0131] FIG. 8B shows the proximity heads 106 and 106 b in a dual wafer surface cleaning and drying system in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 processes the top surface 108 a of the wafer 108 , and the proximity head 106 b processes the bottom surface of 108 b of the wafer 108 . By the inputting of the N 2 /IPA and the DIW by the source inlets 302 and 306 respectively, and by use of the vacuum from the source outlet 304 , the meniscus 116 may be formed between the proximity head 106 and the wafer 108 and between the proximity head 106 b and the wafer 108 . The proximity heads 106 and 106 b , and therefore the meniscus 116 , may be moved over the wet areas of the wafer surface in an manner so the entire wafer 108 can be cleaned and/or dried.
[0132] FIG. 9A illustrates a processing window 538 - 1 in accordance with one embodiment of the present invention. In one embodiment, the processing window 538 - 1 may include a plurality of source inlets 302 and 306 and also a plurality of source outlets 304 . The processing window 538 - 1 is a region on a proximity head 106 (or any other proximity head referenced herein) that may generate and control the shape and size of the meniscus 116 . Therefore, the processing window 538 - 1 may be a region that dries and/or cleans a wafer if the proximity head 106 is desired to be used in that manner. In one embodiment, the processing window 538 - 1 is a substantially rectangular shape. It should be appreciated that the size of the processing window 538 - 1 (or any other suitable processing window described herein) may be any suitable length and width (as seen from a top view).
[0133] FIG. 9B illustrates a substantially circular processing window 538 - 2 in accordance with one embodiment of the present invention. In one embodiment, the processing window 538 - 2 may include a plurality of source inlets 302 and 306 and also a plurality of source outlets 304 . The processing window 538 - 2 is a region on the proximity head 106 (or any other proximity head referenced herein) that may generate and control the meniscus 116 . Therefore, the processing window 538 - 2 may be a region that dries and/or cleans a wafer if the proximity head 106 is desired to be used in that manner. In one embodiment, the processing window 538 - 2 is a substantially circular shape.
[0134] FIG. 9C illustrates a processing window 538 - 3 in accordance with one embodiment of the present invention. In one embodiment, the processing window 538 - 3 may include a plurality of source inlets 302 and 306 and also a plurality of source outlets 304 . The processing window 538 - 3 is a region on the proximity head 106 (or any other proximity head referenced herein) that may generate and control the meniscus 116 . Therefore, the processing window 538 - 3 may be a region that dries and/or cleans a wafer if the proximity head 106 is desired to be used in that manner. In one embodiment, the processing window 538 - 3 is a substantially oval in shape.
[0135] FIG. 9D illustrates a processing window 538 - 4 in accordance with one embodiment of the present invention. In one embodiment, the processing window 538 - 4 may include a plurality of source inlets 302 and 306 and also a plurality of source outlets 304 . The processing window 538 - 4 is a region on the proximity head 106 (or any other proximity head referenced herein) that may generate and control the meniscus 116 . Therefore, the processing window 538 - 4 may be a region that dries and/or cleans a wafer if the proximity head 106 is desired to be used in that manner. In one embodiment, the processing window 538 - 4 is a substantially square shape.
[0136] FIG. 10A shows an exemplary process window 538 - 1 with the plurality of source inlets 302 and 306 as well as the plurality of source outlets 304 in accordance with one embodiment of the present invention. In one embodiment, the process window 538 - 1 in operation may be moved in direction 546 across a wafer during, for example, a wafer drying operation. In such an embodiment, a proximity head 106 may encounter fluids on a wafer surface on a leading edge region 548 . The leading edge region 548 is an area of the proximity head 106 that, in a drying process, encounters fluids first. Conversely a trailing edge region 560 is an area of the proximity head 106 that encounters the area being processed last. As the proximity head 106 and the process window 538 - 1 included therein move across the wafer in the direction 546 , the wet area of the wafer surface enter the process window 538 - 1 through the leading edge region 548 . Then after processing of the wet region of the wafer surface by the meniscus that is generated and controllably maintained and managed by the process window 538 - 1 , the wet region is dried and the dried region of the wafer (or substrate) leaves the process window 538 - 1 through a trailing edge region 560 of the proximity head 106 . As discussed in reference to FIGS. 9A through 9D , the process window 538 - 1 may be any suitable shape such as, for example, rectangular, square, circular, oval, semi-circular, etc.
[0137] FIG. 10B shows processing regions 540 , 542 , and 544 of a proximity head 106 in accordance with one embodiment of the present invention. In one embodiment, the processing regions 540 , 542 , and 544 (the regions being shown by the broken lines) make up the processing window as discussed in reference to FIG. 10A . It should be appreciated that the processing regions 540 , 542 , and 544 may be any suitable size and/or shape such as, for example, circular, ring, semi-circular, square, semi-square, free form, etc. as long as a stable and controllable fluid meniscus can be generated that can apply and remove fluids from a surface in an efficient manner. In one embodiment, the processing region 540 includes the plurality of source inlets 302 , the processing region 542 (also known as a vacuum ring) includes the plurality of source outlets 304 , and the processing region 544 includes the plurality of source inlets 306 . In a preferable embodiment, the region 542 surrounds (or substantially surrounds) the region 544 with a ring of source outlets 304 (e.g., a vacuum ring). The region 540 substantially surrounds the region 544 but has an opening 541 where there are no source inlets 302 exist on a leading edge side of the process window 538 - 1 . In yet another embodiment, the region 540 forms a semi-enclosure around the region 542 . The opening in the semi-enclosure leads in the direction of the scanning/processing by the head 106 . Therefore, in one embodiment, the proximity head 106 can supply a first fluid to a first region of the wafer surface from the region 544 and surround the first region of the wafer with a vacuum region using the region 542 . The proximity head 106 can also semi-enclose the vacuum region with an applied surface tension reducing fluid applied from the region 540 . In such as embodiment, the semi-enclosing generates an opening that leads to the vacuum region.
[0138] Therefore, in operation, the proximity head 106 generates a fluid meniscus by application of N 2 /IPA, DIW, and vacuum, in the regions 540 , 542 , and 544 in the process window 538 (as shown in FIG. 10A ). When the proximity head 106 is moving over the wafer surface in an exemplary drying operation, the wafer surface that moves through the opening 541 in the region 542 and contacts the meniscus 116 within the process window 538 is dried. The drying occurs because fluid that is on that portion of the wafer surface that contacts the meniscus 116 is removed as the meniscus moves over the surface. Therefore, wet surfaces of a wafer may enter the process window 538 through the opening 541 in the region 540 and by contacting the fluid meniscus may undergo a drying process.
[0139] It should be appreciated that although the plurality of source inlets 302 , the plurality of source inlets 306 , and the plurality of source outlets 304 are shown in this embodiment, other embodiments may be utilized where any suitable number of the source inlets 302 , the source inlets 306 , and the source outlets 304 may be utilized as long as the configuration and number of the plurality of source inlets 302 , the source inlets 306 , and the source outlets 306 may generate a stable, controllable fluid meniscus that can dry a surface of a substrate.
[0140] FIGS. 11 through 14 illustrate exemplary embodiments of the proximity head 106 . It should be appreciated any of the different embodiments of the proximity head 106 described may be used as one or both of the proximity heads 106 a and 106 b described above in reference to FIGS. 2A through 5H . As shown by the exemplary figures that follow, the proximity head may be any suitable configuration or size that may enable the fluid removal process as described in FIGS. 6 to 10 . Therefore, any, some, or all of the proximity heads described herein may be utilized in any suitable wafer cleaning and drying system such as, for example, the system 100 or a variant thereof as described in reference to FIGS. 2A to 2 D. In addition, the proximity head may also have any suitable numbers or shapes of source outlets 304 and source inlets 302 and 306 . It should be appreciated that the side of the proximity heads shown from a top view is the side that comes into close proximity with the wafer to conduct wafer processing. All of the proximity heads described in FIGS. 11 through 14 are manifolds that enable usage of the IPA-vacuum-DIW orientation in a process window or a variant thereof as described above in reference to FIGS. 2 through 10 . The embodiments of the proximity head 106 as described below in reference to FIGS. 11 through 14 all have embodiments of the process window 538 , and regions 540 , 542 , and 544 as described in reference to FIGS. 9A through 10B above. In addition, the proximity heads described herein may be utilized for either cleaning or drying operations depending on the fluid that is inputted and outputted from the source inlets 302 and 306 , and the source outlets 304 . In addition, the proximity heads described herein may have multiple inlet lines and multiple outlet lines with the ability to control the relative flow rates of liquid and/or vapor and/or gas through the outlets and inlets. It should be appreciated that every group of source inlets and source outlets can have independent control of the flows.
[0141] It should be appreciated that the size as well as the locations of the source inlets and outlets may be varied as long as the meniscus produced is stable. In one embodiment, the size of the openings to source inlets 302 , source outlets 304 , and source inlets 306 are between about 0.02 inch and about 0.25 inch in diameter. In a preferable embodiment, the size of the openings of the source inlets 306 and the source outlets 304 is about 0.06 inch, and the size of the openings of the source inlets 302 is about 0.03 inch.
[0142] In one embodiment the source inlets 302 and 306 in addition to the source outlets 304 are spaced about 0.03 inch and about 0.5 inch apart. In a preferable embodiment, the source inlets 306 are spaced 0.125 inch apart from each other and the source outlets 304 are spaced 0.125 inch apart and the source inlets 302 are spaced about 0.06 inch apart. In one embodiment, the source inlets 302 , the source outlets 304 may be combined in the form of one or more slots or channels rather than multiple openings. By way of example, the source outlets 304 may be combined in the form of one or more channels that at least partially surrounds the area of the source outlets 306 for the portion of the meniscus. Similarly, the IPA outlets 302 can be combined into one or more channels that lie outside the area of the source inlets 304 . The source outlets 306 can also be combined into one or more channels.
[0143] Additionally, the proximity heads may not necessarily be a “head” in configuration but may be any suitable configuration, shape, and/or size such as, for example, a manifold, a circular puck, a bar, a square, an oval puck, a tube, plate, etc., as long as the source inlets 302 , and 306 , and the source outlets 304 may be configured in a manner that would enable the generation of a controlled, stable, manageable fluid meniscus. A single proximity head can also include sufficient source inlets 302 and 306 , and the source outlets 304 such that the single proximity head can also support multiple meniscuses. The multiple meniscuses can simultaneously perform separate functions (e.g., etch, rinse, and drying processes). In a preferable embodiment, the proximity head may be a type of manifold as described in reference to FIG. 10A through 14C . The size of the proximity heads may be varied to any suitable size depending on the application desired. In one embodiment, the length (from a top view showing the process window) of the proximity heads may be between 1.0 inch to about 18.0 inches and the width (from a top view showing the process window) may be between about 0.5 inch to about 6.0 inches. Also when the proximity head may be optimized to process any suitable size of wafers such as, for example, 200 mm wafers, 300 , wafers, etc. The process windows of the proximity heads may be arranged in any suitable manner as long as such a configuration may generate a controlled stable and manageable fluid meniscus.
[0144] FIG. 11A shows a top view of a proximity head 106 - 1 with a substantially rectangular shape in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 - 1 includes three of the source inlets 302 which, in one embodiment, applies IPA to a surface of the wafer 108 .
[0145] In this embodiment, the source inlets 302 are capable of applying IPA toward a wafer surface region, the source inlets 306 are capable of applying DIW toward the wafer surface region, and the source outlets 304 are capable of applying vacuum to a region in close proximity of a surface of the wafer 108 . By the application of the vacuum, the IPA, DIW, and any other type of fluids that may reside on a wafer surface may be removed.
[0146] The proximity head 106 - 1 also includes ports 342 a , 342 b , and 342 c that, in one embodiment, correspond to the source inlet 302 , source outlet 304 , and source inlet 306 respectively. By inputting or removing fluid through the ports 342 a , 342 b , and 342 c , fluids may be inputted or outputted through the source inlet 302 , the source outlet 304 , and the source inlet 306 . Although the ports 342 a , 342 b , and 342 c correspond with the source inlet 302 , the source outlet 304 , and the source inlet 306 in this exemplary embodiment, it should be appreciated that the ports 342 a , 342 b , and 342 c may supply or remove fluid from any suitable source inlet or source outlet depending on the configuration desired. Because of the configuration of the source inlets 302 and 306 with the source outlets 304 , the meniscus 116 may be formed between the proximity head 106 - 1 and the wafer 108 . The shape of the meniscus 116 may vary depending on the configuration and dimensions of the proximity head 106 - 1 .
[0147] It should be appreciated that the ports 342 a , 342 b , and 342 c for any of the proximity heads described herein may be any suitable orientation and dimension as long as a stable meniscus can be generated and maintained by the source inlets 302 , source outlets 304 , and source inlets 306 . The embodiments of the ports 342 a , 342 b , and 342 c described herein may be applicable to any of the proximity heads described herein. In one embodiment, the port size of the ports 342 a , 342 b , and 342 c may be between about 0.03 inch and about 0.25 inch in diameter. In a preferable embodiment, the port size is about 0.06 inch to 0.18 inch in diameter. In one embodiment, the distance between the ports is between about 0.125 inch and about 1 inch apart. In a preferable embodiment, the distance between the ports is between about 0.25 inch and about 0.37 inch apart.
[0148] FIG. 11B illustrates a side view of the proximity head 106 - 1 in accordance with one embodiment of present invention. The proximity head 106 - 1 includes the ports 342 a , 342 b , and 342 c . In one embodiment, the ports 342 a , 342 b , and 342 c feed source inlets 302 , source outlets 304 , and the source inlets 306 respectively. It should be understood that the ports may be any suitable number, size, or shape as long as the source inlets 302 and 306 as well as source outlets 304 may be utilized to generate, maintain, and manage the meniscus 116 .
[0149] FIG. 11C shows a rear view of the proximity head 106 - 1 in accordance with one embodiment of the present invention. The rear view of the proximity head 106 - 1 , in one embodiment, corresponds to the leading edge 548 of the proximity head 106 - 1 . It should be appreciated that the proximity head 106 - 1 is exemplary in nature and may be any suitable dimension as long as the source inlets 302 and 306 as well as the source outlet 304 are configured in a manner to enable cleaning and/or drying of the wafer 108 in the manner described herein. In one embodiment, the proximity head 106 - 1 includes the input ports 342 c which may feed fluid to at least some of the source inlets 302 a which run parallel to the input ports 342 c shown in FIG. 11C .
[0150] FIG. 12A shows a proximity head 106 - 2 with a partial rectangular and partial circular shape in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 - 2 includes one row of source inlets 306 that is adjacent on both sides to rows of source outlets 304 . One of the rows of source outlets 304 is adjacent to two rows of source inlets 302 . Perpendicular to and at the ends of the rows described above are rows of source outlets 304 .
[0151] FIG. 12B shows a side view of the proximity head 106 - 2 with a partial rectangular and partial circular shape in accordance with one embodiment of the present invention. In one embodiment, the proximity head 106 - 2 includes ports 342 a , 342 b , and 342 c on a side of the proximity head 106 - 2 . The ports 342 a , 342 b , and 342 c may be utilized to input and/or output fluids through the source inlets 302 and 306 and the source outlets 304 . In one embodiment, the ports 342 a , 342 b , and 342 c correspond to the source inlets 302 , the source outlets 304 , and the source inlets 306 respectively.
[0152] FIG. 12C shows a back view of the proximity head 106 - 2 with a partial rectangular and partial circular shape in accordance with one embodiment of the present invention. The back side as shown by the rear view is where the back side is the square end of the proximity head 106 - 2 .
[0153] FIG. 13A shows a rectangular proximity head 106 - 3 in accordance with one embodiment of the present invention. In one embodiment, the proximity head 106 - 3 includes a configuration of source inlets 302 and 306 and source outlets 304 ′ that is similar to the proximity head 106 - 1 as discussed in reference to FIG. 11A . The rectangular proximity head 106 - 3 includes the source outlets 304 ′ that are larger in diameter than the source outlets 304 . In any of the proximity heads described herein, the diameter of the source inlets 302 and 306 as well as the source outlets 304 may be altered so meniscus generation, maintenance, and management may be optimized. In this embodiment, the source inlets 302 are capable of applying IPA toward a wafer surface region, the source inlets 306 are capable of applying DIW toward the wafer surface region, and the source outlets 304 are capable of applying vacuum to a region in close proximity of a surface of the wafer 108 . By the application of the vacuum, the IPA, DIW, and any other type of fluids that may reside on a wafer surface may be removed.
[0154] The proximity head 106 - 3 also includes ports 342 a , 342 b , and 342 c that, in one embodiment, correspond to the source inlet 302 , source outlet 304 , and source inlet 306 respectively. By inputting or removing fluid through the ports 342 a , 342 b , and 342 c , fluids may be inputted or outputted through the source inlet 302 , the source outlet 304 , and the source inlet 306 . Although the ports 342 a , 342 b , and 342 c correspond with the source inlet 302 , the source outlet 304 , and the source inlet 306 in this exemplary embodiment, it should be appreciated that the ports 342 a , 342 b , and 342 c may supply or remove fluid from any suitable source inlet or source outlet depending on the configuration desired. Because of the configuration of the source inlets 302 and 306 with the source outlets 304 , the meniscus 116 may be formed between the proximity head 106 - 1 and the wafer 108 . The shape of the meniscus 116 may vary depending on the configuration and dimensions of the proximity head 106 - 1 .
[0155] It should be appreciated that the ports 342 a , 342 b , and 342 c for any of the proximity heads described herein may be any suitable orientation and dimension as long as a stable meniscus can be generated and maintained by the source inlets 302 , source outlets 304 , and source inlets 306 . The embodiments of the ports 342 a , 342 b , and 342 c described in relation to the proximity head 106 - 1 may be applicable to any of the proximity heads described in reference to the other Figures. In one embodiment, the port size of the ports 342 a , 342 b , and 342 c may be between about 0.03 inch and about 0.25 inch in diameter. In a preferable embodiment, the port size is about 0.06 inch to 0.18 inch in diameter. In one embodiment, the distance between the ports is between about 0.125 inch and about 1 inch apart. In a preferable embodiment, the distance between the ports is between about 0.25 inch and about 0.37 inch apart.
[0156] FIG. 13B shows a rear view of the proximity head 106 - 3 in accordance with one embodiment of the present invention. The rear view of the proximity head 106 - 3 , in one embodiment, corresponds to the leading edge 548 of the proximity head 106 - 3 . It should be appreciated that the proximity head 106 - 3 is exemplary in nature and may be any suitable dimension as long as the source inlets 302 and 306 as well as the source outlet 304 are configured in a manner to enable cleaning and/or drying of the wafer 108 in the manner described herein. In one embodiment, the proximity head 106 - 3 includes the input ports 342 c which may feed fluid to at least some of the source inlets 302 a which run parallel to the input ports 342 c shown in FIG. 13A .
[0157] FIG. 13C illustrates a side view of the proximity head 106 - 3 in accordance with one embodiment of present invention. The proximity head 106 - 3 includes the ports 342 a , 342 b , and 342 c . In one embodiment, the ports 342 a , 342 b , and 342 c feed source inlets 302 , source outlets 304 , and the source inlets 306 respectively. It should be understood that the ports may be any suitable number, size, or shape as long as the source inlets 302 and 306 as well as source outlets 304 may be utilized to generate, maintain, and manage the meniscus 116 .
[0158] FIG. 14A shows a rectangular proximity head 106 - 4 in accordance with one embodiment of the present invention. In one embodiment, the proximity head 106 - 4 includes a configuration of source inlets 302 and 306 and source outlets 304 ′ that is similar to the proximity head 106 - 3 as discussed in reference to FIG. 13A . The rectangular proximity head 106 - 3 includes the source outlets 304 ′ that are larger in diameter than the source outlets 304 . In any of the proximity heads described herein, the diameter of the source inlets 302 and 306 as well as the source outlets 304 may be altered so meniscus generation, maintenance, and management may be optimized. In one embodiment, the source outlets 304 ′ are located closer to the source inlets 302 than the configuration discussed in reference to FIG. 13A . With this type of configuration, a smaller meniscus may be generated. The region spanned by the source inlets 302 , 306 and source outlets 304 ′ (or also source outlets 304 as described in reference to FIG. 11 A) may be any suitable size and/or shape. In one embodiment, the process window may be between about 0.03 square inches to about 9.0 square inches. In a preferable embodiment, the process window may be about 0.75. Therefore, by adjusting the region of the In this embodiment, the source inlets 302 are capable of applying IPA toward a wafer surface region, the source inlets 306 are capable of applying DIW toward the wafer surface region, and the source outlets 304 are capable of applying vacuum to a region in close proximity of a surface of the wafer 108 . By the application of the vacuum, the IPA, DIW, and any other type of fluids that may reside on a wafer surface may be removed.
[0159] The proximity head 106 - 3 also includes ports 342 a , 342 b , and 342 c that, in one embodiment, correspond to the source inlet 302 , source outlet 304 , and source inlet 306 respectively. By inputting or removing fluid through the ports 342 a , 342 b , and 342 c , fluids may be inputted or outputted through the source inlet 302 , the source outlet 304 , and the source inlet 306 . Although the ports 342 a , 342 b , and 342 c correspond with the source inlet 302 , the source outlet 304 , and the source inlet 306 in this exemplary embodiment, it should be appreciated that the ports 342 a , 342 b , and 342 c may supply or remove fluid from any suitable source inlet or source outlet depending on the configuration desired. Because of the configuration of the source inlets 302 and 306 with the source outlets 304 , the meniscus 116 may be formed by the process window between the proximity head 106 - 1 and the wafer 108 . The shape of the meniscus 116 may correspond with the shape of the process window and therefore the size and shape of the meniscus 116 may be varied depending on the configuration and dimensions of the regions of source inlets 302 and 306 and regions of the source outlets 304 .
[0160] FIG. 14B shows a rear view of the rectangular proximity head 106 - 4 in accordance with one embodiment of the present invention. The rear view of the proximity head 106 - 4 , in one embodiment, corresponds to the leading edge 548 of the proximity head 106 - 4 . It should be appreciated that the proximity head 106 - 4 is exemplary in nature and may be any suitable dimension as long as the source inlets 302 and 306 as well as the source outlet 304 are configured in a manner to enable cleaning and/or drying of the wafer 108 in the manner described herein. In one embodiment, the proximity head 106 - 4 includes the input ports 342 c which may feed fluid to at least some of the source inlets 302 a which run parallel to the input ports 342 c shown in FIG. 13A .
[0161] FIG. 14C illustrates a side view of the rectangular proximity head 106 - 4 in accordance with one embodiment of present invention. The proximity head 106 - 4 includes the ports 342 a , 342 b , and 342 c . In one embodiment, the ports 342 a , 342 b , and 342 c feed source inlets 302 , source outlets 304 , and the source inlets 306 respectively. It should be understood that the ports may be any suitable number, size, or shape as long as the source inlets 302 and 306 as well as source outlets 304 may be utilized to generate, maintain, and manage the meniscus 116 .
[0162] FIG. 15A shows a proximity head 106 in operation according to one embodiment of the present invention. It should be appreciated that the flow rate of the DIW and the N 2 /IPA, the magnitude of the vacuum, and rotation/movement of the wafer being processed may be varied in any suitable manner to provide optimal fluid meniscus controllability and management to generate enhanced wafer processing. The proximity head 106 , in one exemplary embodiment, is utilized in a configuration as described in reference to FIG. 2A . As shown in reference to FIGS. 15A through 15F , the wafer is a clear material so fluid meniscus dynamics can be seen with different flow rates, vacuum rates, and wafer rotations. The flow rate of DIW and N 2 /IPA as well as the vacuum and rotation of the wafer may be varied depending on the conditions encountered during drying. In FIG. 15A , the meniscus has been formed by input of DIW and vacuum without any N 2 /IPA flow. Without the N 2 /IPA flow, the meniscus has an uneven boundary. In this embodiment, the wafer rotation is zero and the DIW flow rate is 500 mi/mn.
[0163] FIG. 15B illustrates the proximity head 106 as described in FIG. 15A with IPA input in accordance with one embodiment of the present invention. In this embodiment, the DIW flow rate is 500 ml/min and the N 2 /IPA flow rate is 12 ml/min with the rotation of the wafer being zero. As shown by FIG. 15B , the usage of N 2 /IPA flow has made the boundary of the meniscus more even. Therefore, the fluid meniscus is more stable and controllable.
[0164] FIG. 15C shows the proximity head 106 as described in FIG. 15B , but with the N 2 /IPA flow increased to 24 ml/min in accordance with one embodiment of the present invention. The rotation has been kept at zero and the flow rate of the DIW is 500 ml/min. When the N 2 /IPA flow rate is too high, the fluid meniscus becomes deformed and less controllable.
[0165] FIG. 15D shows the proximity head 106 where the fluid meniscus is shown where the wafer is being rotated in accordance with one embodiment of the present invention. In this embodiment, the rotation of the wafer is 3 rotations per minute. The flow rate of the DIW is 500 ml/min while the flow rate of the IPA is 12 SCFH. The magnitude of the vacuum is about 30 in Hg @ 80 PSIG. When the wafer is rotated, the fluid meniscus becomes less stable due to the added wafer dynamics as compared with FIG. 15C which shows the same DIW and N 2 /IPA flow rate but without wafer rotation.
[0166] FIG. 15E shows the proximity head 106 where the fluid meniscus is shown where the wafer is being rotated faster than the rotation shown in FIG. 15D in accordance with one embodiment of the present invention. In this embodiment, the rotation of the wafer is 4.3 rotations per minute. The flow rate of the DIW is 500 ml/min while the flow rate of the IPA is 12 SCFH. The magnitude of the vacuum is about 30 on Hg @ 80 PSIG. When the wafer is rotated faster, the fluid meniscus has a more uneven boundary as compared to the fluid meniscus discussed in reference to FIG. 15D due to the added wafer dynamics as compared.
[0167] FIG. 15F shows the proximity head 106 where the N 2 /IPA flow has been increased as compared to the N 2 /IPA flow of FIG. 15D in accordance with one embodiment of the present invention. In this embodiment, the variables such as the DIW flow rate, rate of wafer rotation, and vacuum magnitude are the same as that described in reference to FIG. 15D . In this embodiment, the N 2 /IPA flow rate was increased to 24 SCFH. With the N 2 /IPA flow rate increased, the N 2 /IPA holds the fluid meniscus along the border to generate a highly controllable and manageable fluid meniscus. Therefore, even with wafer rotation, the fluid meniscus looks stable with a consistent border that substantially corresponds to the region with the plurality of source inlets 302 and the region with the plurality of source outlets 304 . Therefore, a stable and highly controllable, manageable, and maneuverable fluid meniscus is formed inside of the process window so, in an exemplary drying process, fluid that the proximity head 106 may encounter on a wafer surface is removed thereby quickly and efficiently drying the wafer surface.
[0168] FIGS. 16A through 19B show exemplary embodiments where a wafer that is oriented vertically may be processed by at least one proximity head where by either movement of the wafer and/or movement of-the at least one proximity head, the wafer surface may be processed vertically from top to bottom. It should appreciated that wafer processing as described herein may include cleaning, drying, rinsing, etc. The vertical processing of the wafer can enhance control of the meniscus and reduce random fluid movement on the wafer during wafer processing. Consequently, by use of vertical wafer processing by the proximity head(s) (also known as manifold), wafer processing such as, for example, cleaning, rinsing, and/or drying may be accomplished in an efficient manner. It should be appreciated that the proximity head/manifold may be any suitable configuration or size as long as the proximity head/manifold structure is consistent with the methods and apparatus described herein. In a preferable embodiment, to achieve process uniformity, resident time of the meniscus on the wafer surface is uniform throughout the wafer. Therefore, scanning direction and speed may be controlled so the meniscus area is scanned evenly over the wafer.
[0169] FIG. 16A illustrates a proximity head 106 a beginning a wafer processing operation where the wafer 108 is scanned vertically in accordance with one embodiment of the present invention. In one embodiment, the wafer 108 is oriented in a vertical manner so a top portion 108 c of the wafer 108 is presented for scanning to the proximity head 106 a . In such an orientation, the surface of the wafer being processed is substantially parallel to a processing window 538 of the proximity head 106 a . It should be appreciated that the wafer 108 may be held in place or moved depending on the configuration of the wafer processing system. In one embodiment, as discussed in further detail in reference to FIG. 17A , the wafer 108 is held into place and the proximity head is moved from a top to bottom scanning motion, where a top portion 108 c of the wafer 108 is scanned before a bottom portion 108 d of the wafer 108 . In such an embodiment, the wafer 108 is positioned in a substantially vertical orientation. The position of the wafer 108 with respect to the y-axis can therefore be in any suitable angle as long as the top portion 108 c of the wafer 108 is located higher along the y-axis than the bottom portion 108 d of the wafer 108 . In a preferable embodiment, the wafer 108 is positioned to be vertical along the y-axis. Therefore, in such an embodiment, the proximity head 106 a may move vertically in a downward fashion and process the wafer surface from top to bottom.
[0170] In another embodiment, the proximity head 106 a may be held stationary and the wafer 108 may be moved in a manner such that the wafer surface is processed in a vertical fashion where the top portion 108 c of the wafer 108 is scanned before the bottom portion 108 d of the wafer 108 . It should be appreciated that any suitable device or apparatus may be used to move the proximity head 106 a vertically so as to scan the surface of the wafer 108 . In one embodiment, the proximity head 106 a may be attached to an arm that is then attached to a mechanical device to move the proximity head 106 a in a vertical manner. In another embodiment, the proximity head 106 a may be directly attached to a mechanical device or apparatus that can facilitate movement of the proximity head 106 a close to the surface of the wafer 108 and to move the proximity head 106 from the top portion 108 c of the wafer 108 to the bottom portion 108 d of the wafer 108 .
[0171] It should also be appreciated that a proximity head 106 b (not visible in FIG. 16A but shown as an exemplary embodiment in FIG. 16F and 16G ) may be used along with the proximity head 106 a to process both wafer surfaces on the two sides of the wafer 108 . Therefore, the proximity heads 106 a and 106 b may be utilized, where one of the proximity heads may process one side of the wafer 108 and the other proximity head may process the other side of the wafer 108 . The proximity heads 106 a and 106 b may be any suitable proximity head described herein. In a preferable embodiment, two proximity heads 106 a and 106 b may be oriented so that the processing windows face each other. The processing windows of the two proximity heads may then be oriented in close proximity to each other. In such an embodiment, the space between the processing windows would be large enough so as to be greater than the thickness of the wafer 108 . Therefore, when a meniscus is formed between the two processing windows, the proximity heads 106 a and 106 b may be moved down from above the wafer 108 . It should be appreciated that the proximity heads 106 a and 106 b (or any other proximity heads described herein) may be any suitable distance away from the wafer 108 as long as a stable controllable meniscus may be formed on the surface being processed. In one embodiment, the proximity heads 106 a and 106 b are about 0.1 mm to about 3 mm away from the respective surfaces being processed. In another embodiment, the proximity heads 106 a and 106 b are about 1 mm to about 2 mm away from the respective surfaces being processed, and in a preferable embodiment, the proximity heads 106 a and 106 b are about 1.5 mm away from the respective surfaces being processed. As the proximity head 106 a and 106 b move downward, the meniscus may contact the a top edge of the wafer 108 and one processing window would form a meniscus with one surface of the wafer 108 and the other processing windows would form a meniscus with the other surface of the wafer 108 .
[0172] It should also be appreciated that the wafer processing operation could be started where the proximity heads 106 a and 106 b starts by initially producing the meniscus on the wafer instead of moving the meniscus onto the wafer 108 from above the top portion 108 a.
[0173] FIG. 16B illustrates a wafer processing continuing from FIG. 16A where the proximity head 106 a has started scanning the wafer 108 in accordance with one embodiment of the present invention. In one embodiment, the top surface of the wafer 108 is positioned in a substantially vertical orientation so the top surface of the wafer 108 is visible when view along a horizontal axis. As the proximity head 106 a comes into close proximity of the wafer 108 , the meniscus 116 is formed between the process window 538 of the proximity head 106 a and the wafer surface being processed. In one embodiment, the proximity head 106 a is configured to dry the wafer 108 . In such an embodiment, the process window 538 intelligently controls and manages the meniscus 116 so drying takes place as the meniscus 116 moves from a top portion 108 c of the wafer 108 to the bottom portion 108 d of the wafer 108 . Therefore, as the drying process takes place, the dried portion of the wafer 108 will become larger in a top to bottom direction. The generation of the meniscus is described in further detail above
[0174] By processing the wafer 108 in a vertical orientation from top to bottom, the meniscus 116 may be optimally controlled by limiting the forces acting on the meniscus 116 . In such a vertical orientation, only vertical forces exerted by gravity need be accounted for in the generation of a controlled and manageable meniscus. In addition, by scanning the proximity head 106 in a downward manner from the top portion 108 c of the vertically oriented wafer 108 , the region of the wafer 108 that has already been dried may be kept dried in an optimal manner. This may occur because the fluids or moisture in the wet regions of the wafer 108 not yet processed would not move up against gravity into the already dried regions.
[0175] FIG. 16C shows a continuation of a wafer processing operation from FIG. 16B in accordance with one embodiment of the present invention. In FIG. 16C , the proximity head 106 has almost halfway (and processed about a semi-circle of the wafer 108 ) between the top portion 108 c and the bottom portion 108 d of the wafer 108 .
[0176] FIG. 16D illustrates the wafer processing operation continued from FIG. 16C in accordance with one embodiment of the present invention. In FIG. 16D , the proximity head 106 a has almost finished scanning the wafer surface. In one embodiment, when both the proximity head 106 a and 106 b are processing the respective sides of the wafer 108 , as portions of the meniscus 116 on each side finish processing and are no longer in contact with the wafer 108 , the meniscuses on both sides of the wafer come into contact and become one meniscus.
[0177] FIG. 16E shows the wafer processing operation continued from FIG. 16D in accordance with one embodiment of the present invention. As shown in FIG. 16E , the proximity head 106 a (and 106 b if a dual proximity head device is being utilized), has finished processing the wafer 108 .
[0178] FIG. 16F shows a side view of the proximity heads 106 a and 106 b situated over the top portion of the vertically positioned wafer 108 in accordance with one embodiment of the present invention. In one embodiment, the proximity heads 106 b and 106 a may form the meniscus 116 as described above. The proximity heads 106 a and 106 b may be moved substantially together downward to process the wafer as described in further detail in reference to FIG. 16G .
[0179] FIG. 16G illustrates a side view of the proximity heads 106 a and 106 b during processing of dual surfaces of the wafer 108 in accordance with one embodiment of the present invention. In one embodiment, as the proximity heads 106 a and 106 b move downward from above the wafer 108 . As the meniscus 116 contacts the wafer 108 , the proximity head 106 a forms a meniscus 116 a with the wafer 108 and the proximity head 106 b forms a meniscus 116 b with the wafer 108 . Therefore, the proximity head 106 a may process one side of the wafer 108 and the proximity head 106 b may process the other side of the wafer. As discussed above, it should be understood that the proximity heads 106 a and 106 b may be moved downward, or the wafer 108 may be moved upward, or the proximity heads 106 a and 106 b may be moved downward while the wafer 108 is moved upward. Consequently, the scanning of the wafer 108 may take place using any suitable movement as long as the proximity heads 106 a and 106 b are moved in a downward movement relative to the wafer 108 . By using this relative downward scanning motion, the drying may take place from the top portion 108 a of the wafer 108 to the bottom portion 108 b of the wafer 108 .
[0180] Although FIGS. 16A to 16 G shows the proximity head 106 a moving from off the edge of the wafer 108 across the diameter to leave the edge of the wafer 108 , other embodiments may be utilized where the proximity head 106 a hovers over the wafer 108 near a top edge of the wafer 108 and moves toward the surface of the wafer 108 . Once in close proximity to the wafer surface, the meniscus is formed and the meniscus is scanned down along a diameter of the wafer 108 . In yet another embodiment, the proximity head may process only a portion of the wafer surface.
[0181] FIG. 17A shows a wafer processing system where the wafer is held stationary in accordance with one embodiment of the present invention. In one embodiment, the wafer 108 is held in place by holders 600 . It should be appreciated that the holders 600 may be any suitable type of device or apparatus that can hold the wafer 108 and still enable the scanning of the wafer surface by the proximity head 106 such as, for example, edge grip, fingers with edge attachments, etc. In this embodiment, the proximity head 106 may be held and moved by a proximity head carrier 602 . It should be appreciated that the proximity head carrier 602 may be any suitable type of apparatus or device that can move the proximity head 106 from above the wafer 108 and scan the proximity head 106 in a downward manner while keeping the proximity head 106 in close proximity to the wafer surface. In one embodiment, the proximity head carrier 602 may be similar to the proximity head carrier assembly as shown FIG. 2A except that the wafer is oriented vertically and the proximity head carrier is configured to move from top to bottom in a vertical manner.
[0182] FIG. 17B shows a wafer processing system where the proximity head carrier 602 ′ may be held in place or moved in accordance with one embodiment of the present invention. In one embodiment, the wafer 108 may be held by edge gripper 604 and moved upward. By this upward motion, the wafer 108 may be scanned by the proximity head 106 in a relative downward manner where the proximity head 106 starts scanning the surface of the wafer 108 in the top portion and moves downward. In one embodiment, the proximity head carrier 602 ′ may be kept still and the relative downward scan may be accomplished by the wafer being moved upward while scanning is taking place. In another embodiment, the wafer 108 may be moved upward and the proximity head carrier 602 ′ may be moved downward. Therefore, the relative downward scan may be accomplished in one of many different variations of wafer holder motions and proximity head carrier motions.
[0183] In a preferable embodiment as shown in the bottom portion of FIG. 17B , after the proximity head 106 has scanned over a majority of the wafer 108 and reaches the edge gripper 604 , the holders 600 , such as described in reference to FIG. 17A , may grip the wafer 108 and move it upward to complete the wafer processing. Once the holders 600 grab onto the wafer 108 , the edge gripper 604 may release the wafer 108 . Then another wafer may be moved into position for wafer processing operations by the proximity head 106 .
[0184] FIG. 17C shows a wafer processing system where the proximity head extends about a radius of the wafer 108 in accordance with one embodiment of the present invention. In one embodiment, the wafer processing system may utilize a proximity head that is capable of producing a meniscus that may cover at least a radius of the wafer 108 . In this embodiment, the proximity head 106 may scan a wafer surface from a top portion 108 c to a bottom portion 108 d of the wafer 108 . In another embodiment, two proximity heads 106 may be utilized where one semi-circle of the wafer surface is processed by one of the proximity heads 106 while the other semi-circle of the wafer surface is processed by the other of the proximity heads 106 .
[0185] FIG. 17D shows a wafer processing system where the proximity head 106 moves vertically and the wafer 108 rotates in accordance with one embodiment of the present invention. In one embodiment, the proximity head 106 moves in the fashion as described in reference to FIG. 17C while, at the same time, the wafer 108 is rotated in direction 112 by using rollers 102 a , 102 b , and 102 c as discussed in reference to the above described figures.
[0186] FIG. 18A shows a proximity head 106 - 5 that may be utilized for vertical scanning of a wafer in accordance with one embodiment of the present invention. In one embodiment, the proximity head 106 - 5 is at least as long as the diameter of the wafer 108 so the proximity head 106 - 5 can produce a meniscus that encompasses at least a diameter of the wafer. In another embodiment, the proximity head 106 - 5 is long enough so the meniscus produced by the proximity head 106 - 5 can extend across the diameter of the wafer so as to include the regions of the wafer surface enclosed within the exclusion region. Therefore, by use of the proximity head 106 - 5 , an entire wafer surface may be scanned in one pass. The proximity head 106 - 5 includes source inlets 302 and 306 and source outlets 304 . In one embodiment, there is a plurality of source inlets 306 that is in a shape of a line that is surrounded by a plurality of source outlets 304 that forms a rectangular shape. Two lines of source inlets 302 are adjacent to the plurality of source outlets 304 . In one embodiment, the source inlets 302 and 306 as well as the source outlets 304 may make up the process window where the meniscus 116 may be formed. It should also be appreciated that the proximity head 106 - 5 as well as the other proximity heads described herein may be varied in size to have different sizes and configurations of process windows. By varying the configuration of the process windows, the size, shape, and the functionality of the meniscus may be changed. In one embodiment, the range of sizes of the proximity head, the sizes of the source inlets 302 and 306 as well as source outlets 304 , and the sizes of the ports 342 a , 342 b , and 342 c (as shown in FIGS. 18B and 18C ) are as described above in reference to FIGS. 11-14 . Therefore, the proximity head 106 - 5 may be any suitable size and configuration depending on the application desired.
[0187] For example, if one proximity head is desired to scan an entire 200 mm wafer in one pass, the proximity head 106 - 5 may have to have a process window that produces a meniscus that is at least 200 mm in length. If the exclusionary region of the 200 mm is not desired to be processed, the meniscus may be less that 200 mm in length. In another example, if one proximity head is desired to scan an entire 300 mm wafer in one pass, the proximity head 106 - 5 may have to have a process window that produces a meniscus that is at least 300 mm in length. If the exclusionary region of the 300 mm is not desired to be processed, the meniscus may be less that 300 mm in length. In yet another embodiment, if a semicircle of the wafer is desired to be processed by a proximity head in one pass, the process window may be a size that would produce a meniscus length that is at least a radius of the wafer. Therefore, the size of the manifold, process window, and the meniscus may be changed depending on the application desired.
[0188] FIG. 18B shows a side view of the proximity head 106 - 5 in accordance with one embodiment of the present invention. In this embodiment, the proximity head 106 - 5 also includes ports 342 a , 342 b , and 342 c that, in one embodiment, correspond to the source inlet 302 , source outlet 304 , and source inlet 306 respectively. By inputting or removing fluid through the ports 342 a , 342 b , and 342 c , fluids may be inputted or outputted through the source inlet 302 , the source outlet 304 , and the source inlet 306 . Although the ports 342 a , 342 b , and 342 c correspond with the source inlet 302 , the source outlet 304 , and the source inlet 306 in this exemplary embodiment, it should be appreciated that the ports 342 a , 342 b , and 342 c may supply or remove fluid from any suitable source inlet or source outlet depending on the configuration desired. Because of the configuration of the source inlets 302 and 306 with the source outlets 304 , the meniscus 116 may be formed between the proximity head 106 - 5 and the wafer 108 . The shape of the meniscus 116 may vary depending on the configuration and dimensions of the proximity head 106 - 5 . As shown in FIG. 18B , the portion 342 c and the source inlet 306 may be configured to angle the input of IPA to the surface of the wafer. As discussed above in reference to FIG. 7C and 7D , by use of an angled source inlet 306 , the meniscus may be managed efficiently so the shape of the meniscus may be controlled and maintained in an optimal manner. In one embodiment, source inlet 306 may be angled between about 0 degrees and about 90 degrees in the direction of the source outlet 304 where angle 90 would be pointing toward the wafer and the angle 0 would be pointing inward to the source outlet 304 . In a preferable embodiment, the source inlet 306 is angled about 15 degrees . It should be understood that the source inlet 302 and source outlet 304 may be angled in any suitable angle that may optimize the generation, control, and management of a stable fluid meniscus.
[0189] FIG. 18C shows an isometric view of the proximity head 106 - 5 in accordance with one embodiment of the present invention. The view of the proximity head 106 - 5 shown in FIG. 18C shows a back side opposite the process window which includes connecting holes 580 and aligning holes 582 . The connecting holes 580 may be used to attach the proximity head 106 - 5 to a proximity head carrier. The aligning holes may be utilized to align the manifold depending on the application desired. The proximity head 106 - 5 also includes ports 342 a , 342 b , and 342 , on a side of the proximity head 106 - 5 opposite the leading edge of the proximity head 106 - 5 . It should be appreciated that the configuration and location of the ports 342 a , 342 b , 342 c , and connecting holes 580 , and the aligning holes 582 may be application dependent and therefore may be any suitable configuration and location as long as the meniscus may be managed in accordance with the descriptions herein.
[0190] FIG. 19A shows a multi-process window proximity head 106 - 6 in accordance with one embodiment of the present invention. The proximity head 106 - 6 includes two process windows 538 - 1 and 538 - 2 . In one embodiment, the process window 538 - 2 may use cleaning fluids instead of DIW to clean wafers. The process window 538 - 2 may use any suitable configuration of source inlets and outlets that may apply any suitable type of cleaning fluid to the wafer. In one embodiment, the process window 538 - 2 may include only source inlets that may apply the cleaning fluid. In another embodiment, the process window 538 - 2 may include other configurations and finctions of source inlets and outlets described herein.
[0191] The process window 538 - 1 may then dry the wafer. The process window 538 - 1 may use any suitable configurations of source inlets and source outlets consistent with the configurations and functions described herein for drying a wafer surface. Therefore, by use of multiple process windows multiple functions such as cleaning and drying may be accomplished by one proximity head. In yet another embodiment, instead of multiple process windows being located on one proximity head, multiple proximity heads may be utilized to process the wafer where, for example, one proximity head may clean the wafer and another proximity head may dry the wafer according to the apparatuses and methodology described herein.
[0192] FIG. 19B shows a multi-process window proximity head 106 - 7 with three process windows in accordance with one embodiment of the present invention. It should be appreciated that the proximity head 106 - 7 may include any suitable number of processing windows depending on the number and types of processing desired to be accomplished by the proximity head 106 - 7 . In one embodiment, the proximity head 106 - 7 includes a process window 538 - 1 , 538 - 2 , and 538 - 3 . In one embodiment, the process window 538 - 1 , 538 - 2 , and 538 - 3 are cleaning, rinsing/drying, and drying process windows respectively. In one embodiment, the process window 538 - 1 may form a meniscus made up of DIW to rinse a wafer surface. The process window 538 - 2 may generate a cleaning fluid meniscus to clean a wafer surface. The process windows 538 - 1 and 538 - 2 includes at least one source inlet 306 to apply fluid to the wafer surface. In one embodiment, the process windows 538 - 1 and 538 - 2 may optionally include source inlet 302 and source outlet 304 to generate a stable and controllable fluid meniscus. The process window 538 - 3 may generate the fluid meniscus 116 to dry the wafer. It should be appreciated that the process window 538 - 3 both rinses and dries the wafer surface because the fluid meniscus is made up of DIW. Therefore, different types of process windows may be included in the proximity head 106 - 7 . As discussed in reference to FIG. 19A above, instead of having multiple process windows in one proximity head, multiple proximity heads may be used where one or more of the proximity heads may be used for different purposes such as cleaning, rinsing, drying, etc.
[0193] While this invention has been described in terms of several preferred embodiments, it will be appreciated that those skilled in the art upon reading the preceding specifications and studying the drawings will realize various alterations, additions, permutations and equivalents thereof. It is therefore intended that the present invention includes all such alterations, additions, permutations, and equivalents as fall within the true spirit and scope of the invention.
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A substrate preparation apparatus is provided. The apparatus includes a housing configured to be installed in a substrate fabrication facility. The housing includes a manifold for use in preparing a wafer surface. The manifold is configured to include a first process window in a first portion of the manifold. A first fluid meniscus is capable of being defined within the first process window. Further included is a second process window in a second portion of the manifold. A second fluid meniscus is capable of being defined within the second process window. An arm is integrated with the housing, and the arm is coupled to the manifold, such that the arm is capable of positioning the manifold in proximity with the substrate during operation. The apparatus therefore provides for the formation of multi-menisci over the surface of a substrate using a single manifold.
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FIELD OF THE INVENTION
[0001] The invention is based on a priority application EP03292005.0 which is hereby incorporated by reference.
[0002] The present invention relates to the field of telecommunications, and more particularly without limitation, to multimedia multicast and multimedia broadcast services.
BACKGROUND AND PRIOR ART
[0003] Point to multi point services exist today which allow data from a single source entity to be transmitted to multiple end points. These services are expected to be used extensively over wireless networks. In particular there is a strong interest to provide multimedia broadcast/multicast service over 3G networks.
[0004] The multimedia broadcast/multicast service (MBMS) which is considered for the universal mobile telecommunications systems (UMTS) is a unidirectional point-to-multi point bearer service in which data is transmitted from a single source entity to multiple recipients. 3GPP has defined two modes of operation: (i) the broadcast mode and (ii) the multicast mode.
[0005] The broadcast mode is a unidirectional point-to-multi point transmission of multimedia data from a single source entity to all users in a broadcast area or areas. Data is transmitted to broadcast areas as defined by the network. A broadcast service received by a user equipment involves one or more successive broadcast sessions. A broadcast service might, for example, consist of a single on-going session, e.g. a media stream, or may involve several intermittent sessions over an extended period of time, e.g. messages. An example of a service using the broadcast mode could be advertising or a welcome message to the network. As not all users attached to the network may wish to receive these messages then the user shall be able to enable/disable the reception of these broadcast services on his user equipment. A disadvantage of the broadcast mode is that power control cannot be performed individually for the user equipment.
[0006] The multicast mode enables the unidirectional point-to-multi point transmission of multimedia data from a single source point to a multicast group in a multicast area. Like in the broadcast mode data is transmitted to multicast areas as defined by the network. In the multicast mode there is the possibility for the network to selectively transmit to cells within the multicast area which contain members of a multicast group. Such multicast services allow unidirectional point-to-multi point transmission of multimedia data, e.g. text, audio, picture, video, from a single source point to a multicast group in a multicast area. An example of a service using the multicast mode could be an information service for which a subscription is required, e.g. a football results service for which a subscription is required.
[0007] In the multicast mode data is streamed in parallel from the radio network controller to the node-B for transmission to the user equipment. For further technical information on the multimedia broadcast/multicast service (MBMS) reference is made to ETSI TS 122 146 V5.2.0(2002-03) and 3GPP TS 25.346 V1.3.0(2003-01) the entirety of which is herein incorporated by reference.
[0008] Broadcast and multicast services for other digital wireless communication networks, such as digital TV, DVD-T and DVB-M are also considered in “Broadcast and Multicast Services in Mobile Networks, Ahmavaara K., Jolma P. and Raivio Y.” (http://www.nokia.com/downloads/aboutnokia/research/library/mobile_networks/MNW 9.pdf)
SUMMARY OF THE INVENTION
[0009] The present invention provides a multimedia multicast service method for a digital wireless communication network, such as a UMTS-type network. Such a network has network controllers for controlling of base stations. In the case of UMTS the network controllers are referred to as “radio network controllers” (RNCs) whereas the base stations are referred to as “node-Bs”.
[0010] Multimedia data of the multimedia multicast service is transmitted from the network controller to the base station by means of a single data stream. This compares to the 3GPP MBMS where multiple redundant data streams are established between the RNC and the node-B. This way the present invention enables to make better usage of the available data transmission capacity between the network controller and the base station.
[0011] In the multicast mode when using point to point beareres a separate communication link and a separate data queue is established for each user equipment in a radio cell of the base station which requests the multimedia data. This enables to separately control the transmission power of each one of the communication links.
[0012] In accordance with a preferred embodiment of the invention the data stream from the network controller to the base station is transmitted via a single lub link. The UTRAN lub interface is as such known from the prior art and is specified in 3G TS 25.430 V3.0.0(2000-01), pages 1 to 21. In accordance with the 3GPP MBMS specification multiple lub links or transport bearers are required for transmitting of multiple data streams in parallel from the RNC to the node-B. In contrast the present invention enables to use a single lub link for transmitting of the single data stream containing the multimedia data.
[0013] In accordance with a further preferred embodiment of the invention high speed downlink packet access (HSDPA) is used in order to realize the separate data queues for the multicast service. HSDPA is a packet-based data service which is as such known in the prior art and which has been specified by 3GPP.
[0014] In accordance with a further preferred embodiment of invention the requests of the user equipment for multimedia service are signaled to the network controller. The network controller controls the base station which services the respective user equipment to establish respective separate data queues for streaming of the multimedia data to the user equipment.
[0015] A further aspect of the invention is the provision of multimedia broadcast services and multicast in a digital wireless communication network by means of point to multipoint bearers. As in the multicast mode a single data stream between the network controller and the base station is established for transmitting of the multimedia data. Again this can be implemented by using a single lub link for the single multimedia data stream.
[0016] The multimedia data stream is distributed to a plurality of user equipment in the same radio cell by establishing a single data queue for the plurality of user equipment. In other words a separate data queue is established for each radio cell which is serviced by the base station. Again HSDPA can be used for realization of the data queue.
[0017] In accordance with a further aspect of the invention the usage of point to point or point to multipoint is selected depending on the number of active user equipment per radio cell or per base station. If the number of user equipment is below a threshold value point to point is selected by the network controller or the node-B. If the number of user equipment which is serviced by the base station surpasses a certain threshold level the network controller switches the base station to point to point.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the following preferred embodiments of the invention will be described in greater detail by making reference to the drawings in which:
[0019] FIG. 1 is a block diagram of a telecommunication system with a node-B in multicast mode,
[0020] FIG. 2 is a block diagram of a telecommunication system with a node-B in multicast mode servicing user equipment in two different radio cells,
[0021] FIG. 3 is a block diagram of a telecommunication system with a node-B in a broadcast mode,
[0022] FIG. 4 is a flow chart being illustrative of the selection of the point to point or point to multipoint multicast mode,
[0023] FIG. 5 is a block diagram of a telecommunication system with a node-B in a hybrid broadcast/multicast mode.
DETAILED DESCRIPTION
[0024] FIG. 1 shows a block diagram of wireless telecommunication system, such as a UMTS-type system. Telecommunication system 100 has radio network controller (RNC) 102 . Radio network controller 102 has control module 104 for controlling node-B 106 .
[0025] Node-B 106 has control module 108 for controlling the internal operation of node-B 106 and for receiving control commands from control module 104 of radio network controller 102 .
[0026] Preferably the interface between radio network controller 102 and node-B 106 is based on the lub standard definition. The lub interface is a logical interface for the interconnection of Node-B and Radio Network Controller components of the UMTS Terrestrial Radio Access Network (UTRAN). The radio network control signaling between these nodes is based on the Node B application part (NBAP). The control commands from Radio Network Controller to the Node-B can be transmitted by using the signaling transport related to NBAP signaling across the lub Interface.
[0027] Node-B 106 is coupled to antenna 110 for providing telecommunication services to user equipment (UE) 1 , 2 , 3 . . . .
[0028] In operation server computer 114 is coupled to radio network controller 102 for providing multimedia data stream 116 to radio network controller 102 . For transmission of multimedia data stream 116 from server computer 114 to radio network controller 102 any suitable transmission medium, such as the Internet, can be utilized.
[0029] A single lub link 118 is established between radio network controller and node-B 106 for transmission of multimedia data stream 116 from radio network controller 102 to node-B 106 . Control module 108 of node-B 106 receives a control command from control module 104 of radio network controller 102 . In response control module 108 controls node-B 106 to establish respective separate data queues 120 , 122 , 124 , . . . for each one of the active user equipment, i.e. UE 1 , UE 2 , UE 3 , . . . . Preferably each one of the data queues is d HSDPA queue.
[0030] The data queues 120 , 122 , 124 , . . . serve to buffer multimedia data stream 116 for transmission via antenna 110 to the corresponding user equipment UE 1 , UE 2 , UE 3 , . . . Using of HSDPA in the multicast mode has the advantage that the transmission power can be controlled individually for each one of the user equipment.
[0031] The present invention is particularly advantageous as it enables to use a single lub link 118 for transmission of multi-media data stream 116 from radio network controller 102 to node-B 106 . This way the transmission of multiple redundant multimedia data streams from radio network controller 102 to node-B 106 is avoided. Another advantage is that the point to point multi cast mode in which node-B 106 is operated in the example considered here enables to control the transmission power for each one of the multi cast communication links separately.
[0032] If node-B 106 has HSDPA capability one implementation option is to enhance the MAC-hs functionality in node-B 106 by introducing a duplication function which duplicates multimedia data stream 116 which is received via the single lub link 118 and distributes it internally toward the user equipment specific data queues 120 , 122 , 124 , . . . , i.e. HSDPA priority queues.
[0033] FIG. 2 shows telecommunication system 100 when node-B 106 provides multimedia point to point multi cast service to user equipment UE 1 , UE 2 , UE 3 in radio cell 112 as well as to user equipment UE 1 , UE 2 , UE 3 in another radio cell 126 . In this case control module 108 of node-B 106 receives a control command from control module 104 in order to establish separate data queues for each one of the user equipment in the respective radio cells within different MAC-hs entities 128 and 130 . MAC-hs entity 128 has data queues 120 , 122 , 124 for respective user equipment within radio cell 112 , i.e. UE 1 , UE 2 , UE 3 . Likewise data queues 132 , 134 , 136 are created in MAC-hs entity 130 for respective user equipment within radio cell 126 , i.e. UE 1 , UE 2 , and UE 3 of radio cell 126 . Again it is preferred to implement the data queues as HSDPA priority queues.
[0034] FIG. 3 shows telecommunication system 100 when node-B 106 is in a point to multipoint transmission mode. In this case control module 108 of node-B 106 receives a control command from control module 104 of radio network controller 102 to establish separate data queues 138 , 140 for respective radio cells which are covered by node-B 106 , i.e. radio cells 112 and 126 , respectively. Preferably data queues 138 and 140 are implemented as HSDPA priority queues.
[0035] It is to be noted that as in the point to point multicast mode (c.f. FIG. 1 and FIG. 2 ) only a single lub link 118 is established between radio network controller 102 and node-B 106 for transmission of multimedia data stream 116 . This way efficient usage is made of the available bandwidth resources.
[0036] FIG. 4 shows a corresponding flowchart. In step 200 data transmission is started in the point to point multicast mode as the number of user equipment requesting multimedia services is relatively low. Hence a dedicated data queue is created in the node-B which services the respective user equipment as explained in detail above with reference to FIGS. 1 and 2 .
[0037] In step 202 it is checked if the number of user equipment per radio cell requesting the multimedia service surpasses a predefined threshold level. If this is not the case no action is taken and the check of step 202 is performed again at periodic intervals.
[0038] If the contrary is true the control goes from step 202 to step 204 . In step 204 node-B is switched to the point to multipoint multi cast mode with only one dedicated data queue per radio cell. Preferably this is done on a per cell basis such that a hybrid mode of operation of node-B can result as illustrated in FIG. 5 .
[0039] In the example shown in FIG. 5 , there are nine user equipment UE 1 , UE 2 , . . . UE 9 within radio cell 112 which request the multimedia service. In radio cell 126 there are just three user equipment, UE 1 , UE 2 , UE 3 which request the multimedia service. As a consequence a determination is made by control module 104 in accordance with the method as illustrated in FIG. 4 that the streaming to the user equipment within radio cell 126 is to be performed in a point to point multicast mode whereas the streaming through the user equipment within radio cell 112 is to be performed in a point to multipoint multi cast mode.
[0040] Control module 108 receives a corresponding control command from control module 104 and controls node-B 106 to establish a single data queue 142 for transmitting of multimedia data stream 116 to the user equipment within radio cell 112 and to establish separate data queues 144 , 146 , 148 for respective user equipment in radio cell 126 , i.e. UE 1 , UE 2 and UE 3 or radio cell 126 .
[0041] It is to be noted that the control module 104 can be implemented in the node-B or that the control function of control module 104 is shared by node-B and the radio network controller.
List of Reference Numerals
[0042]
100 telecommunication system
102 RNC
104 control module
106 node-b
108 control module
110 antenna
112 radio cell
114 server computer
116 multimedia data stream
118 lub link
120 data queue
122 data queue
124 data queue
126 radio cell
128 MAC-hs entity
130 MAC-hs entity
132 data queue
134 data queue
136 data queue
138 data queue
140 data queue
142 data queue
144 data queue
146 data queue
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A method of providing a multimedia multicast service in a digital wireless communication network, the network having a network controller for controlling of at least one base station, comprising establishing a single data stream from the network controller to the base station for transmitting of multimedia data, by means of a single lub link or transport bearer and establishing a separate communication link and a separate data queue for each user equipment in a radio cell of the base station which requests the multimedia data.
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BACKGROUND OF THE PRESENT INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a warm air exhaust clothes drying machine, and more particularly to a safe clothes drying machine with a large space structure using a sealing cover made of soft material, wherein the heat source is located at the bottom of the sealing cover while the water vapor is exhausted at the top of the sealing cover.
[0003] 2. Description of Related Arts
[0004] From the time humanity invented clothes, clothes became a part of human civilization. Modern, civilized humans view the washing of various types of clothes with importance. In today's homes, electronic drying machines for drying washed clothes are in the forms of barrel-shaped dedicated drying machine and composite machines for both washing and drying. However, such products produce wrinkles in the dried clothes and damage the clothes. In addition, the prices of the machines fall between $1000 and $10000. Such a price range only matches the needs of a high income fraction of the population and is out of the reach of a broad salary range. A cabinet type clothes drying machine made of surrounding panels (metallic boards, composite boards, and glass boards) also appeared on the market, but because the structure is complex, the size is large, and the transport volume is large, the cost of the machine is high, and its price is around $125. For the average consumer, the price is still too high.
[0005] In recent years, those skilled in the art developed a simple cloth covered warm air exhaust clothes drying machine. There is competition to develop a wave of low-priced, novel, and scientific clothe drying tools to meet the needs of the people.
[0006] The following clothes drying machines were found through a patent search:
[0007] China patent CN98234374.4 disclosed a clothes drying machine.
[0008] China patents CN99226450.2 and 99226450.2 disclosed a rapid clothes drying cabinet.
[0009] China patent CN02272023.5 disclosed a clothes drying machine.
[0010] China patent CN200420014883.3 a warm air clothes drying machine.
[0011] The common features of the above disclosed clothes drying machines are:
[0012] 1. The connecting column for the inside of the clothes drying chamber is in the form of a central column-type primary pole. A top bracket is connected to the top of the primary pole. The bottom of the primary pole is slipped into the center of the exhaust mechanism at the bottom. The bottom surface of the exhaust plate has a plurality of support pieces to suspendedly support the whole body of the clothes drying machine.
[0013] 2. The cloth cover for preventing leakage of warm air is made of a heat resistant and soft material. A zipper for adding and removing clothes is disposed at the front of the cloth cover. The advantages of such a covering are low cost of manufacture, excellent ability to prevent leakage of warm air, and convenience of use.
[0014] 3. Warm air is blow through the exhaust plate at the bottom of the central support column. The warm air rises into the clothes drying chamber. Such a structure takes full advantage of the physical phenomenon of the rising of warm air and benefits the drying of clothes.
[0015] However, the following disadvantages exist:
[0016] 1. As disclosed in CN02272023.5 and CN20040014883.3, the exhaust port is around the bottom of the primary pole. A person skilled in the art knows through analysis or use that the temperature just outside the exhaust port is high. If a user uses a clothes drying machine of such a structure to dry long clothes, the bottom of the clothes will be close to the exhaust port, and the high temperature current from the exhaust port will damage the clothes and cause the user to sustain losses.
[0017] 2. Using the above exhaust port structure for a clothes drying machine, if a large article of clothing slides from the hanger during use of the machine, and the article of clothing falls on the central exhaust port and blocks the port, then the high temperature current is concentrated at the exhaust plate, burning the article of clothing and possibly causing a fire.
[0018] 3. A central column-shaped primary pole connects to the top bracket for hanging clothes at the top and to the middle of the exhaust mechanism at the bottom, thus connecting the main parts of the interior of the clothes drying chamber. Such a structure takes space in the interior, rendering the hanging of clothes inconvenient. Also, the support offered by a single central column is poor. If clothes are hung on a single side, then it is easy to lose balance and harm the machine. In addition, the placement of the central column support in the middle of the exhaust mechanism causes the high temperature exhaust to heat the bottom of the column, leading to hazards during use.
[0019] Application CN200610109222.2, titled “A Cabinet-type Clothes Drying Machine” (illustrated in FIG. 1 ) and by the present inventor, discloses a cabinet-type clothes drying machine, wherein warm air buffer chamber partitioning board 16 forms warm air buffer chamber 15 above warm air tunnel protection board 14 , and humidity probe 12 and temperature probe 13 are used to calibrate the temperature and humidity controlling heater for the warm air buffering chamber and the clothes drying chamber. Because the cabinet-type clothes drying machine comprises a warm air buffering chamber partitioning board 16 disposed above the warm air tunnel protection board 14 and a temperature probe 12 , the invention solves the problems of damaging the dried clothing and the high temperature current damaging articles of clothing and causing a fire in the case of an article of clothing falling onto the exhaust port. The features are: 1. The warm air buffering chamber is made of a cloth cover, and the straight support columns are supported by the bottom casing. 2. The structure is relatively complex, and installation is complex. 3. The current generator is on one side of the bottom casing, and the cross section for current flowing from the air tunnel is limited. In other words, part of the space is occupied by the current generator, and there is some positional bias in the air in the warm air buffering chamber, creating a low temperature section above the current generator in the warm air buffering chamber and the clothes drying chamber and high temperature sections above the openings for current flow.
[0020] Application CN200620018906.7 by the present inventor discloses a tent-shaped clothes drying machine (illustrated in FIG. 2 ), comprising support bracket 6 and heater 1 mounted on support bracket 6 . An arch-shaped exhaust dome 2 is mounted at the top of the heater 1 . A lower support pipe 5 is connected to the trough axis of the arch-shaped exhaust dome 2 , and an upper support pipe 4 is connected to the lower support pipe 5 . The features are: Current guiding flakes 3 are evenly disposed around exhaust port 9 of the arch-shaped exhaust dome, a waterproof cover 10 is disposed on the arch-shaped exhaust dome and below the lower support pipe 5 , and the bottom of the support bracket 6 comprises integral support legs 7 , each support leg 7 having a wheel 8 . The current guiding flakes in the invention successfully guide the warm air and improve the current flow. The warm air current does not cascade horizontally but flow upward, thus achieving excellent drying with low energy expenditure. Heat resistant and low heat-conducting plastic current guiding flakes remain within safe temperatures during use, firmly support the support pipes, and does not allow conduct the high temperature from the exhaust dome to the upper support pipe. The wheels allow movement of the clothes drying machine and provide convenience. The upper support pipe and the lower support pipes are connected via a screw mechanism, allowing for easy storage. The tent-shaped clothes drying machine has a low price, $25 each, and falls within the consumptive powers of the general population. However, the safety of the machine is inferior. The same problem of high temperature current damaging the clothing exists. The important problems are: 1. The outer perimeter surrounding the warm air exhaust port is made of a cloth cover, but the cloth cover has low rigidity. During use, a child who inadvertently displaces the cloth cover may be burned. 2. There is a column in the middle of the clothes drying chamber that occupies room in the clothes drying chamber, introducing difficulties in hanging large articles of clothing and leaving cooling clothes.
SUMMARY OF THE PRESENT INVENTION
[0021] A main object of the present invention to solve the above problems in the prior art by providing a safe clothes drying machine with a large space structure.
[0022] The safe clothes drying machine with a large space structure is practiced as follows:
[0023] A safe clothes drying machine with a large space structure, comprises a clothes drying chamber, a warm air buffer chamber, a fan chamber for heated air generator and controller, wherein the clothes drying chamber, warm air buffer chamber, and fan chamber are independent parts arranged in a top to bottom manner.
[0024] According to the safe clothes drying machine with a large space structure, the warm air buffer chamber is a basin-shaped casing with a top opening and is disposed below the clothes drying chamber. An air inlet for connecting to the fan chamber for generating heated air is disposed at the bottom of the basin-shaped casing. A current guide safety cover is disposed at the top opening of the basin-shaped casing. A securing mechanism for securing the clothes drying chamber is disposed at the top opening of the basin-shaped casing.
[0025] According to the safe clothes drying machine with a large space structure, the basin-shaped casing of the warm air buffer chamber is made by injection mold plastic or stretched metal, wherein the surrounding wall is connected to the bottom wall in an arc shaped structure; and a plurality of cup shaped or flake shaped reinforcement ribs are disposed around the outer perimeter of the casing, or the surrounding walls and bottom wall of the casing are configured in a protruded-indented structure.
[0026] According to the safe clothes drying machine with a large space structure, wherein the clothes drying chamber comprises a barrel-shaped cloth cover, a top bracket for supporting the barrel-shaped cloth cover, and a supporting assembly for supporting the top bracket. The top bracket is formed by a perimeter bracket and a rack bracket mounted on the perimeter bracket. The perimeter bracket forms the framework of the clothes drying chamber by connecting to the securing mechanism via the supporting assembly. The barrel-shaped cloth cover comprises exhaust holes formed at the top surface, and flexible airtight barrel walls, wherein the barrel-shaped cloth cover is disposed on the framework of the clothes drying chamber.
[0027] According to the safe clothes drying machine with a large space structure, the supporting assembly comprises a plurality of support poles, wherein the bottom of the perimeter bracket of the top bracket and the top opening of the basin-shaped casing has a plurality of matching attachment holes, and the support poles are inserted into the matching attachment holes on the bottom of the perimeter bracket of the top bracket and the top opening of the basin-shaped casing.
[0028] Or, the supporting assembly comprises a plurality of support pipes, wherein the securing mechanisms on the bottom of the perimeter bracket of the top bracket and the top opening of the basin-shaped casing are evenly disposed matching protrusion pillars, and the support pipe are fixed to the protrusion pillars on the bottom of the perimeter bracket of the top bracket and the top opening of the basin-shaped casing to form the framework of the clothes drying chamber.
[0029] Or, the supporting assembly comprises a plurality of support rows, wherein the support rows are formed of two support poles or support pipes with connecting poles or pipes between, the connecting poles or pipes having a horizontal or triangular configuration. The support pole or pipe has a plurality of indented slots for supporting the cloth hanger.
[0030] Or, the supporting assembly comprises a plurality of support boards, wherein the securing mechanism on the bottom of the perimeter bracket of the top bracket and the top opening of the basin-shaped casing is a groove or sideways screws. The support boards are securing to the top bracket and the basin-shaped casing through the groove or screws, forming the framework of the clothes drying chamber.
[0031] At least two attachment holes or protrusion pillars are on the bottom of the perimeter bracket and the top opening of the basin-shaped casing, and at least two of the support poles or support pipes are provided correspondingly.
[0032] According to the safe clothes drying machine with a large space structure, a circumferential outwardly protruding ring is disposed around the top opening of the basin-shaped casing. A tightening mechanism is disposed at the bottom of the barrel-shaped cloth cover. The bottom of the barrel-shaped cloth cover is set on the circumferential outwardly protruding ring around the top opening of the basin-shaped casing and sealed to the top opening of the basin-shaped casing through the tightening mechanism, and a pulling lock is installed on one side of the barrel-shaped cloth cover, thus forming the clothes drying chamber.
[0033] According to the safe clothes drying machine with a large space structure, the fan chamber for generating heated air is disposed on the bottom exterior of the basin-shaped casing of the fan chamber for generating heated air. The air inlet on the bottom of the basin-shaped casting is optimally placed in the middle of the bottom of the casing. The fan chamber for generating heated air comprises a fan, a heat-resistant exhaust canopy disposed on the outer shell of the fan, a heating element between the exhaust canopy and the fan, and a filter placed in the shell of the fan corresponding to the position of the blades of the fan.
[0034] According to the safe clothes drying machine with a large space structure, an exhaust canopy or exhaust grating is disposed on the air inlet at the bottom of the basin-shaped casing. A water guarding protruding ring is disposed around the bottom canopy of the basin-shaped casing, and water drains are disposed at the bottom of the basin-shaped casing away from the canopy, so as to drain water from the machine after hanging clothes from the washing machine in the clothes drying chamber.
[0035] According to the safe clothes drying machine with a large space structure, the exhaust canopy, which is a column-shaped horizontal exhaust canopy, protrudes from the bottom of the casing, wherein the column-shaped horizontal exhaust canopy has a cylindrical shaped body with a sealed top and a plurality of exhaust ports formed at the surrounding wall of the body. Each exhaust port has a horizontal current guiding board. Or the exhaust canopy is a hemispherical exhaust canopy, wherein the hemispherical shell of the exhaust canopy having multiple horizontal, vertical, or spiral exhaust ports. A current guiding board having a corresponding shape is provided at each exhaust port. An umbrella-shaped water guard is provided at the top side of the exhaust canopy, the umbrella-shaped water guard has an outer diameter slightly larger than the projection of the exhaust canopy.
[0036] According to the safe clothes drying machine with a large space structure, the exhaust canopy is a grating disposed on the air inlet at the bottom of the casing.
[0037] According to the safe clothes drying machine with a large space structure, the current guide safety cover is made of a heat-resistant plastic or metal board, the current guide safety cover having a plurality of fine ventilating holes evenly distributed on the surface, the ventilating holes having an area of 0.5 mm 2 to 100 mm 2 . The ratio area of the ventilating holes to the area of the current guide safety cover is 1:20 to 1:0.5. The current guide safety cover is affixed to the top opening of the basin-shaped casing by a pressure ring or screws. Or, protrusions are disposed on the inner wall of the basin-shaped casing, wherein the current guide safety cover is affixed to the protrusions on the inner wall of the basin-shaped casing by a pressure ring or screws. The ventilating holes evenly distributed on the surface of the current guide safety cover. Or, the current guide safety cover has a non-holed zone, i.e. the area corresponding to the exhaust canopy is a non-holed zone, with a water channel disposed around the non-holed zone under the current guide safety cover. The non-holed zone and water channel have an outer diameter slightly larger than the projection of the exhaust canopy so as to prevent the water dripped from the clothes in the clothes drying chamber from flowing into the fan chamber for generating heat.
[0038] The safe clothes drying machine with a large space structure further comprises a plurality of support legs disposed circumferentially under the basin-shaped casing of the warm air buffer chamber, wherein the support legs are sufficiently long enough to suspendedly support the fan chamber for generating heated air above ground. Each of the support legs has a leg wheel at an end. The support legs are surrounded by a holed planer skirt or further comprise a plurality of integral support legs disposed below the fan, each support leg having a leg wheel.
[0039] The safe clothes drying machine with a large space structure further comprises a humidity probe located inside the clothes drying chamber and a temperature probe located inside the warm air buffer chamber, wherein the humidity probe and the temperature probe are electrically connected to the controller.
[0040] According to the safe clothes drying machine with a large space structure, the basin-shaped casing of the warm air buffer chamber is made of an air-tight double walled basin-shaped casing made of plastic or metal plating.
[0041] The advantages of the present invention are the followings.
[0042] 1. The clothes drying chamber of the present invention is formed by a barrel-shaped cloth cover, a top bracket supporting the barrel-shaped cloth cover, a basin-shaped casing forming the warm air buffer chamber, a supporting assembly connecting the basin-shaped casing and the perimeter of the top bracket, a fan chamber for generating heated air, and bottom support legs. The structure is simple; it is easy to disassemble, transport, and install; and the consumer may install the machine in a small amount of time.
[0043] 2. Because the top bracket and the basin-shaped casing of the warm air buffer chamber are integral, the structure is stable and strong, the cost of manufacture is low, and the speed of manufacture is fast. The plurality of support poles or support legs offers good support for the weight of hanged clothes.
[0044] 3. The warm air buffer chamber formed by the open top basin-shaped casing and the current guide safety cover on the top opening provides the maximum area of even warm current and dry clothes hanged in any position.
[0045] 4. A plurality of ventilating holes is disposed on the current guide safety cover. The current guide safety cover blocks the continuously emitted warm air from the exhaust canopy. Guided by the horizontal current guiding boards on the exhaust canopy, most of the warm air follows the horizontal current guiding boards' direction and temporarily flow toward the perimeter of the warm air buffer chamber, thus mixing with the cooler air in the warm air buffer chamber and distributing the molecules with higher and lower kinetic energy. As a result, the high temperature air from the fan chamber for generating heated air mixes in this large space to form a clothes drying warm air within usable temperatures. A temperature probe is installed in the warm air buffer chamber or the clothes drying chamber to control the temperature of the warm air buffer chamber or the clothes drying chamber. The temperature probe is connected to a temperature modulator, which controls the electrical current flow to an electrical heating element. Thus, the temperature in the warm air buffer chamber under the current guide safety cover is evenly regulated. This temperature-regulated warm air is separated by the small holes on the current guide safety cover, which increases the quality of clothes drying.
[0046] 5. There are two installation positions for the temperature probe: The first is near the perimeter of the warm air buffer chamber in order to detect the temperature of the air entering the clothes drying chamber. The other is at the current guiding safety cover in order to detect the temperature of the air flowing into the clothes drying chamber to directly control the temperature of the air flowing into the clothes drying chamber and provide the user with the ability to control the temperature used for clothes of a variety of materials.
[0047] 6. The fan is installed outside of the warm air buffer chamber, effectively separating the warm air buffer chamber and the fan chamber for generating heated air, thus preventing the warm air from the warm air buffer chamber from affecting the electrical components inside the fan.
[0048] 7. The temperature probe is installed in the warm air buffer chamber or the clothes drying chamber to measure the local temperature and transmit the measurement to the controller to start or stop the heating element in the fan chamber for generating heated air, thus regulating the temperature in the warm air buffer chamber or the clothes drying chamber. The humidity probe is installed in the clothes drying chamber and transmits data to the controller. The clothes drying machine is automatically controlled and is, safe, energy efficient, fast, accurately controlled, and stops when clothes are dry. The machine satisfies the need for high quality home electronics.
[0049] 8. The walls of the warm air buffer chamber are insulating materials of a certain thickness, within the chamber is installed a temperature probe, and the temperature of the warm air is regulated within a safe temperature range. If during use, a child inadvertently touches the warm air buffer chamber or the safety board above the chamber, he will not be burned by high temperature current emitted from an exhaust port. When clothes fall onto and cover the safety cover board, the warm air buffer chamber will not damage the clothes because of the temperature probe. Because the safety cover is connected to the casing, if the machine is tipped over to a horizontal position, clothes will not block the exhaust ports.
[0050] 9. The clothes drying machine of the present invention has a clear assembly method and unique structure. It is stable, strong, scientific, and safe. It is easy to manufacture and easy to package. The price of the machine is appropriate for the average consumer and is suitable for propagation.
[0051] These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] FIG. 1 is a perspective view illustrating the conventional clothes drying machine with a cloth cover.
[0053] FIG. 2 is a perspective view illustrating the conventional cabinet-type clothes drying machine with a cloth cover.
[0054] FIG. 3 is a schematic view of a safe clothes drying machine with a large space structure according to a preferred embodiment of the present invention.
[0055] FIG. 4 is a sectional view illustrating the cross sectional shape of the basing-shaped casing according to the above preferred embodiment of the present invention.
[0056] FIG. 5 is a sectional view illustrating the shape of the top bracket according to the above preferred embodiment of the present invention.
[0057] FIG. 6 is a perspective view of the current guide safety cover without a water guarding zone disposed in the top opening of the basin-shaped casing of the warm air buffering chamber according to the above preferred embodiment of the present invention.
[0058] FIG. 7 is a perspective view of the current guide safety cover with a water guarding zone disposed on the top opening of the basin-shaped casing of the warm air buffering chamber according to the above preferred embodiment of the present invention.
[0059] FIG. 8 is a perspective view of the current guide safety cover without a water guarding zone disposed on the top opening of the basin-shaped casing of the warm air buffering chamber according to the above preferred embodiment of the present invention.
[0060] FIG. 9 is a schematic view illustrating a plurality of bottom support legs disposed around the perimeter of the bottom of the basin-shaped casing of the warm air buffering chamber and the current guide safety cover disposed within the basin-shaped casing according to the above preferred embodiment of the present invention.
[0061] FIG. 10 is a schematic view of the basin-shaped casing of a warm air buffer chamber, the basin-shaped casing having a holed planer skirt and a plurality of support legs below according to the above preferred embodiment of the present invention.
[0062] FIG. 11 is a schematic view of a support row connecting the top bracket and the basin-shaped casing according to the above preferred embodiment of the present invention.
[0063] FIG. 12 illustrates an alternative mode of the support row connecting the top bracket and the basin-shaped casing according to the above preferred embodiment of the present invention.
[0064] FIG. 13 a schematic view of a flake shaped connecting board connecting a pair of support poles or support pipes according to the above preferred embodiment of the present invention.
[0065] FIG. 14 is a schematic view of the support board according to the above preferred embodiment of the present invention.
[0066] FIG. 15 is schematic view illustrating a hemispherical exhaust canopy according to the above preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0067] Referring to FIG. 3 of the drawings, a safe clothes drying machine with a large space structure according to a preferred embodiment of the present invention is illustrated, wherein the safe clothes drying machine comprises a clothes drying chamber 21 , a warm air buffer chamber 22 , a fan chamber 23 for heated air generator and controller, wherein the clothes drying chamber 21 , warm air buffer chamber 22 , and fan chamber 23 are independent parts of the machine and are arranged in a top to bottom manner. The warm air buffer chamber 22 is a basin-shaped casing 221 with a top opening and is disposed below the clothes drying chamber 21 . The cross sectional area of the basin-shaped casing 221 matches with the cross sectional area of the clothes drying chamber 21 . An air inlet 222 is disposed at the bottom of the basin-shaped casing 221 for connecting to the fan chamber 23 for generating heated air. A current guide safety cover 223 is disposed at the top opening of the basin-shaped casing 221 . A securing mechanism, which comprises a plurality of installation holes or protrusion pillars 224 as shown in FIG. 4 , for securing the clothes drying chamber 21 is disposed at the top opening of the basin-shaped casing 221 .
[0068] The basin-shaped casing 221 of the warm air buffer chamber 22 is made by injection mold plastic or stretched metal, wherein the surrounding wall is connected to the bottom wall in an arc shaped structure to prevent any dead air zone within the basin-shaped casing 221 when the warm air is circulating therewithin, so as to enhance the warm air being evenly distributed within the basin-shaped casing 221 . A plurality of cup shaped or flake shaped reinforcement ribs are disposed around the outer perimeter of the casing, or the surrounding walls and bottom wall of the casing are configured in a protruded-indented structure, so as to strengthen the overall structure of the basin-shaped casing 221 and improve its efficiency.
[0069] The clothes drying chamber 21 comprises a barrel-shaped cloth cover 211 , a top bracket 212 for supporting the barrel-shaped cloth cover 211 , and a supporting assembly 213 for supporting the top bracket 212 at its periphery. The supporting assembly 213 comprises a plurality of support poles, support pipes, or the like. The clothes drying chamber 21 is defined at a space between the current guide safety cover 223 and the top bracket 212 . The top bracket 212 is formed by a perimeter bracket 214 and a rack bracket 215 mounted on the perimeter bracket 214 , as shown in FIGS. 3 and 5 . A plurality of protrusion pillars 224 , or installation holes, are evenly formed at the bottom of the perimeter bracket 214 of the top bracket 212 corresponding to the top opening of the basin-shaped casing 221 , wherein the support poles or support pipes 224 are affixed to the protrusion pillars 224 on the bottom of the perimeter bracket 214 of the top bracket 212 and the top opening of the basin-shaped casing 221 to form the framework of the clothes drying chamber 21 . The barrel-shaped cloth cover 211 comprises exhaust holes formed at the top surface, and flexible airtight barrel wall, wherein the barrel-shaped cloth cover 211 is disposed on and supported by the framework of the clothes drying chamber 21 . A tightening mechanism 217 is disposed at the bottom of the barrel-shaped cloth cover 211 . A pulling lock (not shown in the figure) is provided on one side of the barrel-shaped cloth cover 211 , wherein the barrel-shaped cloth cover 211 is supported by the top bracket 212 at a position that the top side of the barrel-shaped cloth cover 211 matches with the top bracket 212 while the barrel wall is dropped down from the top bracket 212 to form the clothes drying chamber 21 The bottom opening of the barrel-shaped cloth cover 211 is sealed and tightened at the top side of the warm air buffer chamber 22 via the tightening mechanism 217 .
[0070] In order to seal and tighten the bottom opening of the barrel-shaped cloth cover 211 at the top side of the warm air buffer chamber 22 , a circumferential outwardly protruding ring 228 is formed at the bottom of the barrel-shaped cloth cover 211 . The bottom opening of the barrel-shaped cloth cover 211 can envelop with the protruding ring 228 . Accordingly, the length of the barrel wall of the barrel-shaped cloth cover 211 is long enough to envelop with the protruding ring 228 when the barrel wall is dropped down from the top bracket 212 . Therefore, the tightening mechanism 217 can be operated to seal and tighten the bottom opening of the barrel-shaped cloth cover 211 at the top side of the warm air buffer chamber 22 , so as to form an entrance of the clothes drying chamber 21 for placing the clothes therein or taking the clothes out. Preferably, there are two different types of the tightening mechanism 217 . The first type thereof is rope type that a rope sleeve is provided at the bottom opening of the barrel-shaped cloth cover 211 such that a rope is slidably passing along the rope sleeve. Therefore, when two ends of the rope are pulled and tied, the bottom opening of the barrel-shaped cloth cover 211 is shrunk to tighten at the warm air buffer chamber 22 . The second type of the tightening mechanism 217 is elastic rope type that an elastic rope is provided at the bottom opening of the barrel-shaped cloth cover 211 to secure at the warm air buffer chamber 22 by the elastic force.
[0071] At least two attachment holes or protrusion pillars 216 are on the bottom of the perimeter bracket 214 and the top opening of the basin-shaped casing 221 , and at least two of the support poles or support pipes are provided correspondingly. The support poles or support pipes are coupled with the attachment holes or protrusion pillars 216 at the perimeter bracket 214 and top opening of the basin-shaped casing 221 .
[0072] When the safe clothes drying machine is designed for small capacity use (such as only one or two clothes replacement in hotel), the support poles or support pipes can be made for parallel strengthen support, wherein the machine is only need to support by two parallel support or just one strengthen to fulfill the top bracket 212 , as shown in FIG. 15 . The zipper door can make bigger. After the user open the zipper door, the operation space for them to place or take out their clothes has become much flexible. Preferably, there are two types of support enhancement to strength the support of the support poles or support pipes. The first one is that a plurality of connecting poles or pipes are formed between two support poles or support pipes to form a support row. Each of the connecting poles has a horizontal configuration 218 as shown in FIG. 12 or triangular configuration 219 as shown in FIG. 11 . The support pole or pipe with the horizontal configuration 218 has a plurality of indented slots 220 for supporting the cloth hanger. Accordingly, each of the connecting poles with the horizontal configuration 218 or the triangular configuration 219 is coupled between the support poles or support pipes preferably by welding to form the support row. Another type of support enhancement is that using plate shape metal plate or plate shape plastic plate as the combination of the support poles or support pipes as shown in FIGS. 13 and 15 .
[0073] The shape of the perimeter bracket 214 and the opening of the basin-shaped casing 221 , i.e. the cross section of the clothes drying chamber 21 , can be made in round shape, oval-shape, square shape, rectangular shape, or the combination of the round and rectangular shape.
[0074] As shown in FIG. 9 , the fan chamber 23 comprises a fan 231 , a heat-resistant exhaust canopy 24 disposed on the outer shell of the fan 213 as shown in FIG. 3 , a heating element 232 between the exhaust canopy 24 and the fan 231 , and a filter 233 placed in the shell of the fan 231 corresponding to the position of the blades of the fan 231 . The fan chamber 23 is disposed on the bottom exterior of the basin-shaped casing 221 by the following two methods. The first method is that the casing of the fan chamber 23 is made by injection mold plastic or stretched metal, or metal pressure-filled method, wherein the interior components is installed into the fan chamber 23 through the opening thereof or through the air inlet of the fan chamber 23 such that the inlet door can be coupled at the air inlet after the interior components are installed into the fan chamber 23 . Another method is that the fan chamber 23 is coupled with the air inlet 222 via screws, wherein the air inlet 22 on is optimally placed in the middle of the bottom of the basin-shaped casting such that the warm air can be evenly distributed at the fan chamber 23 .
[0075] A sealing ring is provided between the fan chamber 23 and the basin-shaped casing to prevent the warm air being leaked out from the fan chamber 23 . Moreover, it further, prevents the warm air leaking out the fan chamber 23 to cause overheat of the body of the machine. The fan chamber 23 further comprises a control unit connecting with en electrical outlet.
[0076] An exhaust canopy 24 or exhaust grating 25 is disposed on the air inlet 222 at the bottom of the basin-shaped casing. A water guarding protruding ring 229 is disposed around the bottom canopy 24 of the basin-shaped casing, and water drains 200 are disposed at the bottom of the basin-shaped casing away from the canopy 24 , so as to drain water from the machine after hanging clothes from the washing machine in the clothes drying chamber.
[0077] There are preferably three different types of exhaust canopy 24 . The first type of exhaust canopy 24 , which is a column-shaped horizontal exhaust canopy, protrudes from the bottom of the casing, wherein the column-shaped horizontal exhaust canopy 24 has a cylindrical shaped body with a sealed top and a plurality of exhaust ports 241 formed at the surrounding wall of the body. Each exhaust port has a horizontal current guiding board. A current guiding board having a corresponding shape is provided at each exhaust port 241 to guide the air flowing between every two of the current guiding board. The top side of the column-shaped horizontal exhaust canopy 24 is air-sealed such that when the warm air flows from the fan chamber 23 vertically towards the column-shaped horizontal exhaust canopy 24 , the warm air will bound to change its direction to form a horizontal warm air. Each layer of the column-shaped horizontal exhaust canopy 24 has at least one exhaust port 241 such that the warm air flows to the column-shaped horizontal exhaust canopy 24 , the column-shaped horizontal exhaust canopy 24 can evenly distribute the warm air. Accordingly, the warm air is guided to spread out in a horizontal direction at 360° to evenly distribute around the warm air buffer chamber 22 in an air circulating manner.
[0078] The air is guided to flow to 360 horizon direction to full with the warm air buffer chamber 22 such that it is beneficial to produce even distribution hot air and good air circulation within the air buffer chamber 22 . Therefore, the warm air is capable of reaching every area of the clothes drying chamber 21 to warm the air therewithin so as to achieve the better efficiency of cloth drying.
[0079] The second type of the exhaust canopy 24 ′ is a hemispherical exhaust canopy, as shown in FIG. 14 , wherein the hemispherical shell of the exhaust canopy 24 ′ has multiple horizontal, vertical, or spiral exhaust ports. A current guiding board having a corresponding shape is provided at each exhaust port. The hemispherical shell of the exhaust canopy 24 ′ guides the warm air flowing out in a radial manner. An umbrella-shaped water guard 243 is provided at the top side of the exhaust canopy 24 ′, wherein the umbrella-shaped water guard 243 has an outer diameter slightly larger than the projection of the exhaust canopy 24 ′. The third type of the exhaust canopy is a grating 25 disposed on the air inlet 22 at the bottom of the casing, wherein the grating 25 can be either protruded or not protruded from the bottom of the casing.
[0080] The current guide safety cover 223 is made of a heat-resistant plastic or metal board, wherein the current guide safety cover 223 has a plurality of fine ventilating holes evenly distributed on the surface. The ventilating holes have an area of 0.5 mm 2 to 100 mm 2 . The ratio area of the ventilating holes to the area of the current guide safety cover is 1:20 to 1:0.5. Preferably, there are two installation methods for the current guide safety cover 223 . The first installation method is that the current guide safety cover 223 is affixed to the top opening of the basin-shaped casing by a pressure ring or screws, as shown in FIGS. 7 and 8 . The second installation method is that protrusions 225 are disposed on the inner wall of the basin-shaped casing, wherein the current guide safety cover 223 is affixed to the protrusions 225 on the inner wall of the basin-shaped casing by a pressure ring or screws, as shown in FIG. 9 . Preferably, there are two configurations of the ventilating holes. The first configuration is that the ventilating holes are evenly distributed on the surface of the current guide safety cover 223 , as shown in FIGS. 6 and 8 . The second configuration is that the current guide safety cover 223 has a non-holed zone 226 , i.e. the area corresponding to the exhaust canopy is a non-holed zone, as shown in FIGS. 3 and 7 , with a water channel 227 disposed around the non-holed zone 226 under the current guide safety cover 223 . The non-holed zone 226 and water channel 227 have an outer diameter slightly larger than the projection of the exhaust canopy 24 , wherein the exhaust canopy 24 comprises a sealing ring to prevent the water dripped from the exhaust canopy 24 into the fan chamber 23 .
[0081] In other words, the machine of the present invention prevents the water dripped from the clothes in the clothes drying chamber 21 to the fan chamber 23 by two structures. The first structure is that the current guide safety cover 224 provides the non-holed zone 226 and the water channel 227 disposed around the non-holed zone 226 under the current guide safety cover 223 . The non-holed zone 226 and water channel 227 have an outer diameter slightly larger than the projection of the exhaust canopy so as to prevent the water dripped from the clothes in the clothes drying chamber 21 from flowing into the fan chamber 23 , so as to prevent the heat generator in the fan chamber 23 from being damaged. The second structure is that the umbrella-shaped water guard 243 is provided at the top side of the exhaust canopy 24 ′, wherein the umbrella-shaped water guard 243 has an outer diameter slightly larger than the projection of the exhaust canopy 24 ′.
[0082] Therefore, by forming the umbrella-shaped water guard 243 is provided at the top side of the exhaust canopy 24 ′, the warm air will detour by the umbrella-shaped water guard 243 to prevent the warm air from directly flowing to the current guide safety cover 223 and the clothes drying chamber 21 . In other words, the warm air is guided to flow horizontally by the umbrella-shaped water guard 243 to produce even distribution warm air and good air circulation within the air buffer chamber 22 . Therefore, the warm air is capable of reaching every area of the clothes drying chamber 21 to warm the air therewithin so as to achieve the better efficiency of cloth drying.
[0083] There are two types of support legs for the machine. The first type is that at least three support legs 28 disposed circumferentially under the basin-shaped casing of the warm air buffer chamber 22 , wherein the vertical portions of the support legs 28 are slidably inserted into the bottom peripheral edge of the warm air buffer chamber 22 . Accordingly, the support legs 28 are sufficiently long enough to suspendedly support the fan chamber 23 for generating heated air above ground. Each of the support legs 28 has a leg wheel 29 at an end. The support legs 28 are surrounded by a holed planer skirt 30 , as shown in FIG. 10 , wherein the holed planer skirt 30 forms as a net shaped panel. The second type is that the support legs 26 are extended below the fan via screws, each support leg 26 having a leg wheel 266 .
[0084] The holed planer skirt 30 has the following two advantages. The holed planer skirt 30 highly improves the efficiency of the machine. Another one is to prevent the shredded paper or the plastic bag falling at the air inlet of the fan so as to prevent the shredded paper or the plastic bag blocking the filter by means of suction force. In other words, if the shredded paper or the plastic bag is stunk at the air inlet of the fan, the air is unable to enter into the air inlet to cause the overheat or abnormal operation of the fan. It is worth mentioning that the through holes at the holed planer skirt 30 enables the air entering to the air inlet of the fan. After the holed planer skirt 30 is installed, the power switch is formed in a box shape and is put inside the holed planer skirt 30 or the outer side wall of the casing.
[0085] The first type of the basin-shaped casing with at least three support legs 28 provides a good support of the casing without limiting the size thereof. The second type of support leg 26 is good for supporting a relatively small size of casing that fits for one to five clothes therein. Because the casing has smaller size and lighter weight, it is much appropriate for connecting to the support leg 26 .
[0086] The two above mentioned types of support legs 28 , 26 can evenly distribute the weight of the machine.
[0087] The safe clothes drying machine further comprises a humidity probe located inside the warm air buffer chamber 22 or a temperature probe located inside the clothes drying chamber 21 , wherein the humidity probe and the temperature probe are electrically connected to the controller. When the humidity is lower than the preset value, the controller can be automatically turned off. In other words, when the clothing is dried, the machine will automatically turn off to achieve the goal of energy saving and much safety.
[0088] Moreover, there are two different structures for locating the air inlet and the fan. The first structure is that the air inlet is located at the peripheral edge of the casing at the bottom thereof. The second structure is that the air inlet is located at the sidewall of the casing. The two above mentioned structures can provide a better air guiding configuration for guiding the air flowing far away from the air outlet. Since the location of the air exit is relocated, the position of the support leg will be correspondingly changed. The first type of the support leg can be remained the same that the support legs are disposed circumferentially under the basin-shaped casing of the warm air buffer chamber 22 . The second type of the support leg will be altered that the support legs are extended at the center or the center portion of the basin-shaped casing.
[0089] Accordingly, the basin-shaped casing made of plastic or metal to form a single wall structure. Therefore, the warm air can easily transmit through the wall of the warm air buffer chamber 22 . In order to achieve a better energy saving and safety purpose, the basin-shaped casing of the warm air buffer chamber 22 is made of plastic or metal to form a double walled structure that air is filled between the double walled structure as a heat insulation layer for minimizing the heat loss within the basin-shaped casing through the wall thereof. There are two advantages of having the double walled structure: one is to reduce the energy waste, and another one is to always keep outer surface of the basin-shaped casing at low temperature for safety purpose.
[0090] One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
[0091] It will thus be seen that the objects of the present invention have been fully and effectively accomplished. The embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.
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A clothes drying machine, particularly a safe clothes drying machine with a large space structure is disclosed. It includes a clothes drying chamber, a warm air buffer chamber, a fan chamber for heat supply and a controller, wherein the clothes drying chamber, warm air buffer chamber and fan chamber for heat supply are independent parts assembled in turn from top down, and the warm air buffer chamber disposed under the clothes drying chamber is a basin-shaped casing with an opening upwards and an air inlet attached to the fan chamber for heat supply is disposed at the bottom of the basin-shaped casing is provided with a fixing device for clothes drying chamber. The clothes drying chamber according to the present invention is consisted of six elements, that is to say, a barrel-shaped cloth cover, a top bracket for supporting the barrel-shaped cloth cover, a basin-shaped casing making up warm wind buffer chamber, support pieces pinned to the basin-shaped casing and circumference edges of the top bracket, a fan chamber for heat supply as well as bottom support legs. Its advantages exist in large space, safety for use, simple structure and convenience to disassemble, transport and install. It will only take a little time for the consumers to finish installation.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to foreign French patent application No. FR 1202729, filed on Oct. 12, 2012, the disclosure of which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
The invention relates to a method for estimating the transverse component of the velocity of the air and applies notably to the field of laser anemometry.
BACKGROUND
Onboard equipment making it possible to estimate the speed of the air with respect to the carrier of the said device exists in the prior art. The carrier is for example an aircraft.
In particular, Doppler LiDARs can be used to measure the speed and the direction of the wind by backscattering of a laser beam on particles of aerosol type carried by the wind. The frequency shift between the emitted wave and the backscattered wave makes it possible to obtain the longitudinal velocity information. The longitudinal velocity is the wind velocity component along the laser sighting axis. Combining measurements arising from at least three non-coplanar sighting axes then makes it possible to access the three components of the velocity vector.
In the field of aeronautics, a Doppler LiDAR customarily generates a laser beam using a laser source, the said beam being focused a certain distance from the aircraft. Particles present in the atmosphere, that is to say aerosols, backscatter the incident beam. The Doppler frequency corresponding to the deviation between the frequency of the backscattered beam and that of the incident beam is detected by an interferometer so as to characterize the speed of the aircraft with respect to the wind.
The frequency shift corresponding to the Doppler frequency is directly proportional to the longitudinal component of the relative speed of the carrier with respect to the air, the longitudinal component being the component along the laser sighting axis.
It is known that the Doppler frequency f Doppler has the value:
f Doppler = 2 × V long λ
in which expression:
V long represents the projection on the laser sighting axis of the vector V corresponding to the speed of the aircraft with respect to the air; λ represents the wavelength of the emitted beam.
Doppler laser anemometry is increasingly being used in systems for estimating the speed of aircraft since it makes it possible to perform a direct measurement, remotely, without any protruding element and independently of the conventional means relying essentially on pressure measurements.
A particular operating regime called the monoparticle regime is of interest here. In this regime, the laser beam is strongly focused in such a way that each particle traversing it produces an individually detectable signal.
The signal generated during the traversal of the Gaussian laser beam by a particle is customarily designated by the word “burst”. It can be viewed as the product of a signal of sinusoidal frequency equal to the Doppler frequency and of a Gaussian window. The width of this Gaussian window is dependent on the width of the laser beam at the point where the particle traverses it and on the transverse velocity of the particle at this same point.
Depending on the point at which the particle crosses the beam, the curvature of the wavefronts of the beam can moreover induce a variation in the frequency of the signal backscattered around the Doppler frequency. The frequency-modulated signal is then designated by the word “chirp”.
The relative speed of the carrier with respect to the air can be represented by a vector V expressed in a three-dimensional reference frame. Conventional use of a laser beam makes it possible to obtain only the projection of this vector on the axis of the beam.
The modulus of the vector representative of the speed of the aircraft with respect to the air mass which carries it is called the “True Air Speed”.
To estimate the true air speed, customarily designated by the acronym TAS, a combination of measurements arising from at least three non-coplanar beams is therefore required.
The simultaneous emission of a plurality of beams exhibits numerous drawbacks in practice. In particular, this involves the implementation of several telescopes for emission/reception of the beam whose integration on aircraft may turn out to be constraining and expensive.
Moreover, the distribution of the laser power according to several measurement axes is less effective in terms of detection sensitivity.
Finally, if the measurements are performed in a zone where the velocity of the particles is disturbed by the carrier, the determination of the modulus of the velocity on the basis of measurements performed at various points may turn out to be complex.
SUMMARY OF THE INVENTION
An aim of the invention is notably to alleviate the aforementioned drawbacks.
For this purpose the subject of the invention is a method for estimating the transverse component V trans of the velocity of the air. It comprises the following steps:
a. emitting a focused laser beam; b. acquiring an electrical signal s(t) resulting from the transit of a particle across the beam at a point of transit; c. analysing the signal s(t) so as to obtain a spectrogram revealing an elongate mark representative of the said transit; d. estimating the duration D of traversal of the laser beam by the particle and the slope P of the mark; e. deducing from the duration D and from the slope P the distance z 0 between the point of traversal of the beam and the focusing point; f. determining the radius ω(z 0 ) of the beam at the point of transit; g. deducing the transverse component V trans from the radius ω(z 0 ) and from the duration D.
The electrical signal s(t) is for example produced by an optical detector illuminated by the coherent mixing of a reference beam with the wave backscattered during the transit.
According to one aspect of the invention, a step determines the Doppler frequency f Doppler of s(t) corresponding to the deviation between the frequency of the backscattered beams and the incident beam, the longitudinal component of the velocity of the air being deduced from this deviation. The distance z 0 is determined using for example the following expression:
z 0 i = P i · D i 2 · λ · z R 2 8 · ω 0 2
in which:
i is the index of the current particle for which the beam traversal is analysed;
ω 0 is the radius at the emitted laser beam focusing point;
λ is the wavelength of the emitted beam;
and Zr is the Rayleigh length associated with the beam and which can be calculated according to the expression:
z
R
=
π
·
ω
0
2
λ
The radius of the beam is determined for example using the expression:
z 0 i = P i · D i 2 · λ · z R 2 8 · ω 0 2
in which:
z
R
=
π
·
ω
0
2
λ
The duration D is for example estimated by measuring the width of the mark appearing in the spectrogram.
The slope P of the mark is for example determined using the following expression:
P = ∫ ( f inst ( t ) - f Doppler ) ( t - t 0 ) p ( t ) ⅆ t ∫ ( t - t 0 ) 2 p ( t ) ⅆ t
in which:
t 0 represents the instant at which the amplitude of the signal is a maximum, the particle then passing closest to the axis of the beam. It can be determined with the aid of a barycentre calculation
t
0
=
∫
∫
t
·
S
(
t
,
f
)
ⅆ
t
ⅆ
f
∫
∫
S
(
t
,
f
)
ⅆ
t
ⅆ
f
;
f
inst
=
∫
f
·
S
(
t
,
f
)
ⅆ
f
∫
S
(
t
,
f
)
ⅆ
f
;
p
(
t
)
=
∫
S
(
t
,
f
)
ⅆ
f
.
In one embodiment, the component V trans is determined using the following expression:
V
trans
i
=
2
·
ω
(
z
0
i
)
D
i
The modulus V of the velocity of the air can be determined by averaging the modulus of the velocity of the particles that have cut the beam in a predetermined range of distance from the focusing point such that:
|z 0 |<Threshold_z 0
Threshold_z 0 being a predetermined threshold value.
According to another aspect of the invention, the time frequency analysis is carried out with the aid of an FFT fast transform.
The modulus V of the velocity of the air can be estimated by using the following expression:
V =√{square root over ( V long 2 +V trans 2 )}
The subject of the invention is also an anemometer comprising a circuit for emitting a convergent laser beam and for receiving the reflections of the said beam in its environment and a processing unit, the said anemometer implementing the method described above.
The subject of the invention is also a computer program comprising instructions for the execution of the method described above, when the program is executed by a processor.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention will become apparent with the aid of the description which follows given by way of nonlimiting illustration, offered with regard to the appended drawings among which:
FIG. 1 gives an exemplary beam traversed by a particle on which the transverse and longitudinal components of the velocity appear;
FIG. 2 presents a method making it possible to estimate the modulus of the vector V representative of the air speed;
FIG. 3 represents an exemplary spectrogram on which the parameters f Doppler , D and P appear;
FIG. 4 gives an exemplary architecture that can be implemented in a laser anemometry device according to the invention;
FIG. 5 illustrates in a simplified manner an embodiment of the module for estimating the true speed.
DETAILED DESCRIPTION
The method according to the invention affords access to the transverse component of the velocities of particle traversing a single beam of a LiDAR operating in the mono-particle regime. The method utilizes the time-frequency characteristics of the signal resulting from the transit of a particle in a laser beam so as to determine the diameter of the beam at the point where the particle has cut it. These time-frequency characteristics are for example the slope, the frequency variation and the duration of traversal. It is then possible to deduce the transverse component of the velocity from the estimated diameter and from the duration of traversal. Finally, by combining the transverse velocity and the longitudinal velocity, one deduces therefrom the modulus of the velocity of an individual particle traversing the beam of a LiDAR.
FIG. 1 gives an exemplary beam traversed by a particle on which the transverse and longitudinal components of the velocity appear.
The beam portion represented is centred around the beam focusing point, that is to say around the location where the radius of the laser beam is a minimum. This location is customarily designated by the word “waist”.
The axis 100 is the axis of propagation of the laser beam. In this example, the LiDAR operates in mono-particle regime thereby implying that the laser beam emitted 101 is convergent. A particle of aerosol type 102 traversing the beam at a distance z 0 from its focusing point is represented. When the particle traverses the beam, a signal resulting from the backscattering of the laser beam can be used to determine the components of a vector V representative of the air speed. Two components of this vector are represented in FIG. 2 . The first component is the longitudinal velocity component V long already explained and the second is the transverse velocity component V trans . The transverse velocity component V trans corresponds to the orthogonal projection of the vector V in the plane orthogonal to the axis 100 of the laser beam.
FIG. 2 presents a method making it possible to estimate the modulus of the vector V representative of the air speed.
Accordingly, a step 200 is implemented so as to acquire an electrical signal s(t) resulting from the transit of a particle in the laser beam.
In the subsequent description, a Gaussian laser beam of radius ω 0 at the focusing point and of wavelength λ is considered. A particle of index i, travelling with a speed V i and cutting the beam at a distance z 0i from the focusing point is also considered.
The amplitude of the electrical signal resulting from the transit of a particle in the laser beam at a given point called the point of transit is a linear chirp s(t) of Gaussian envelope whose simplified expression is given hereinbelow:
s
(
t
)
=
A
0
·
exp
(
-
8
·
(
t
-
t
0
)
2
D
2
)
·
cos
(
2
π
(
f
Doppler
(
t
-
t
0
)
+
P
(
t
-
t
0
)
2
2
)
+
Φ
0
)
In a second step 201 , a time-frequency analysis of the signal s(t) is carried out. This analysis can be performed to obtain a spectrogram, that is to say a diagram associating a frequency spectrum of s(t) with various instants t. To determine it, a fast Fourier transform (FFT) can be used. During the traversal of the beam by the particle, the analysis of the signal s(t) reveals an elongate mark in the spectrogram.
The result of the time-frequency analysis of s(t) is then processed 202 so as to obtain a set of estimations which is representative of the traversal of the beam by the particle, in particular:
the central frequency of s(t) which is equal to the Doppler frequency f Doppler i of the chirp; the duration D i of traversal of the beam by the particle at the point of transit and which can be defined, by convention, as the duration for which the amplitude of the backscattered signal is greater than or equal to 1/e 2 of the peak amplitude, where e represents Euler's number defined by e=exp(1)˜2.718 or else as the base of the natural logarithm that is to say such that In(e)=1; the slope P i of the elongate mark representative of s(t) in the spectrogram or more rigorously the rate of variation of the frequency over time.
These parameters are then used to determine 202 the components of the air speed.
The Doppler frequency f Doppler i is used to determine the longitudinal component of the air speed. Accordingly, the following expression can be used:
V
long
i
=
λ
2
f
Doppler
i
The parameters D i and P i are used in the following step to determine the transverse component of the air speed. Initially, the distance z 0i from the focusing point is deduced from the slope P i and from the duration D i by using for example the following expression:
z 0 i = P i · D i 2 · λ · z R 2 8 · ω 0 2
in which:
z
R
=
π
·
ω
0
2
λ
Subsequently, the radius of the beam at the place where the particle traverses the beam is calculated on the basis of the distance from the focusing point z 0i . Accordingly, the following expression can be used:
ω
(
z
0
i
)
=
ω
0
1
+
(
z
0
i
z
R
)
2
It is then possible to determine the transverse component of the air speed, it being possible to use the following expression:
V
trans
i
=
2
·
ω
(
z
0
i
)
D
i
Finally, the modulus of the air speed (TAS) is determined 203 by averaging the modulus of the velocity of the particles that have cut the beam in a predetermined range of distance between the point of transit and the focusing point such that:
|z 0 |<Threshold_z 0
This average can be computed over a time horizon compatible with the passband, typically 50 ms for a passband of 10 Hz.
The threshold Threshold_z 0 can be chosen such that z 0 =z R is about 5 mm for ω 0 =50 μm.
FIG. 3 represents an exemplary spectrogram on which the parameters f Doppler , D and P appear.
In this exemplary spectrogram, the evolution of the time is represented as abscissa and the frequencies as ordinate. The time is expressed in microseconds and the frequencies in megahertz.
The amplitude of the spectrogram is represented by a grey scale 301 so as to reveal various ranges of amplitudes expressed in decibels.
This exemplary spectrogram represents a measurement performed during the transit of a particle of aerosol type across the laser beam emitted. An elongate mark appears in dark grey and represents the chirp resulting from the transit of the particle through the beam.
The central frequency of this mark corresponds to the Doppler frequency f Doppler and if the value of the spectrogram at the time t and at the frequency f is denoted S(t, f), it may be determined on the basis of a barycentre calculation with the following expression:
f
Doppler
=
∫
∫
f
·
S
(
t
,
f
)
ⅆ
t
ⅆ
f
∫
∫
S
(
t
,
f
)
ⅆ
t
ⅆ
f
The duration D of traversal of the beam by a particle is deduced from the following expression:
σ 2 = E [ t 2 ] - E [ t ] 2 = ∫ ∫ ( t - t 0 ) 2 · S ( t , f ) ⅆ t ⅆ f ∫ ∫ S ( t , f ) ⅆ t ⅆ f
In which:
σ represents the temporal standard deviation;
E[.] represents the expectation function.
One is customarily interested in the duration at 1/e 2 of the maximum equal to D=4σ.
The slope P of the mark is deduced from the following expression:
P = ∫ ( f inst ( t ) - f Doppler ) ( t - t 0 ) p ( t ) ⅆ t ∫ ( t - t 0 ) 2 p ( t ) ⅆ t
in which:
t 0 represents the instant at which the amplitude of the signal is a maximum, the particle then passing closest to the axis of the beam. It can be determined with the aid of a barycentre calculation
t
0
=
∫
∫
t
·
S
(
t
,
f
)
ⅆ
t
ⅆ
f
∫
∫
S
(
t
,
f
)
ⅆ
t
ⅆ
f
;
f inst = ∫ f · S ( t , f ) ⅆ f ∫ S ( t , f ) ⅆ f ; p ( t )=∫ S ( t,f ) df.
FIG. 4 gives an exemplary architecture that can be implemented in a laser anemometry device according to the invention.
The function of a first module 400 is to acquire the signal s(t). Accordingly, means well known to the person skilled in the art can be used to receive the optical signal resulting from the reflection of the laser beam on the particle as well as means for converting the said optical signal into an electrical signal and digitizing it. The signal s(t) is shaped in such a way that its central frequency is substantially equal to the Doppler frequency.
Once the signal s(t) is available, a module 401 carrying out a Fast Fourier Transform (FFT) is used. This module shapes the results obtained after the transform so as to obtain a spectrogram such as that presented with the aid of FIG. 3 .
A module 402 can then analyse the spectrogram so as to obtain an estimation 404 of the parameters f Doppler , D and P, as described previously.
The parameters thus estimated 404 are thereafter processed by a module 403 for estimating the true speed V.
FIG. 5 illustrates in a simplified manner an embodiment of the module 403 for estimating the true speed.
The estimated parameters f Doppler , D and P are used as input to this module.
D and P are used to successively estimate the distance between the spot where the particle traverses the beam and the focusing point z 0 500 , the radius of the beam at the level of the particle of aerosol type ω(z 0 ) 501 and the transverse component V trans 502 , as described previously.
The frequency f Doppler is used in parallel to estimate 503 the longitudinal component V long .
The modulus of the true speed can thereafter be estimated 504 by using Pythagoras' theorem:
V =√{square root over ( V long 2 +V trans 2 )}
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A method for estimating the transverse component V trans of the velocity of the air comprises the following steps: emitting a focused laser beam; acquiring an electrical signal resulting from the transit of a particle across the beam at a point of transit; analyzing the signal so as to obtain a spectrogram revealing an elongate mark representative of the transit; estimating the duration of traversal of the laser beam by the particle and the slope of the mark; deducing from the duration and from the slope the distance between the point of traversal of the beam and the focusing point; determining the radius of the beam at the point of transit; deducing the transverse component from the radius and from the duration.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for increasing the effectiveness of the utilization of target-seeking ammunition articles, which include a sensor scanning a predetermined searching surface within the target area for target criteria in order to suppress dummy targets during evaluation for steering towards or homing on the target.
The employment of such methods is implemented for target-seeking ammunition in order to possibly avoid any attack against dummy targets and, thereby an ineffective utilization of the ammunition. This so-called intelligent ammunition can relate in the same measure to ballistically-fired ammunition, as well as to ammunition with their own propulsion devices (remote-controlled or self-steering projectiles or missiles); so that when, hereinafter, for purposes of simplifying the representation there is set forth a discussion of projectiles, no restriction is meant to apply to any specific types of target-seeking ammunition.
2. Discussion of the Prior Art
The usual methods of the foregoing technological type are based on an extraction of target data which are obtainable by means of active or passive position-finding devices; for instance, from the geometry, the radiation characteristics or the kinematics of targets of interest through means for mathematical data processing on board of the projectile in comparison with pregiven typical properties of this type, in order to avoid an attack against dummy targets, and to ensure favorable attack conditions for an optimum probability of disabling the target of interest. A typical example of data-processing techniques which can be employed for this purpose is described in German Patent No. 29 49 453 for a complex system, or is described in U.S. Pat. No. 4,444,110 for a simpler target-detection sensor system.
SUMMARY OF THE INVENTION
The present invention is predicated on the recognition that with representable signal processing technology applied to the searching surface which is scanned by the sensor of the projectile within the target area, there cannot be implemented the separation out or distinguishing of collective dummy targets, inasmuch as there will always remain a few detected target locations which cannot be distinguished with regard to the evaluated criteria from actual real targets of interest, or in any case not with the necessary degree of certainty. As a result, there is produced a certain degree of probability of attacking a false target; in essence, a predetermined limit to the effectiveness of the utilization of the projectile with respect to the intended disabling of real targets which are of actual interest.
Based on this recognition, it is an object of the invention that even after exhausting all realistic technological signal-processing capabilities with respect to the target information which is obtained within the searching surface, to find a further criterium for the distinction of real targets in comparison with the still remaining false targets, and to thereby achieve an increase in the effectiveness of the utilization of the projectiles.
The foregoing object is essentially achieved through a method of the above-mentioned type in that presently, upon the detection of a target within pregiven target surroundings, a search is conducted thereabout for a further target, and after detecting a predetermined number of such types of neighboring targets, one such target is approached.
The foregoing object is also based on the recognition that in a combat zone, typical real targets, such as vehicle columns, will be encountered relatively frequently, and thereby will exhibit a substantially smaller average distance or spacing with respect to each other in contrast with false targets which can no longer be eliminated by position-finding techniques within the bounds of the searching surface. Isolatedly encountered false targets which are dispersed within the searching surface are thereby characterized in that they will be individually encountered within a certain target region; whereas real targets located within a comparable target region will presently at least be located proximate to one further target. Based on this recognition, the false targets will be most extensively precluded during steering towards or homing onto a target, that only such targets will be considered which are located at a pregiven proximity with at least one further target, from which there again is conducted a search for a closely adjacent further target, and so forth. When, in this manner, during approach to the target area there is detected within the searching surface a series of relatively closely neighboring targets, then with a high degree of probability this relates to real targets, in all instances with individual false targets dispersed therein; isolated located (false) targets in the searching surface are not conducive to such a series formation in the detection of relatively closely neighboring targets, and thus will not be considered during the target approach or homing in of the projectile. An attack against a target then follows only when such a series of neighboring targets is determined to be above a certain number. Upon the firing of a plurality of projectiles into the same target area; in effect, with mutually overlapping searching surfaces, provision can also be made that the different projectiles are preset to a different number of targets which are detected in sequence within the series or chain, in order to possibly avoid superfluously attacking a single target a number of times.
In this manner, already for the individual projectiles, but first really with regard to the employment of a large number of projectiles fired in a spread will there significantly rise the degree of effectiveness, namely the probability of destroying real targets which are of actual interest, beyond the degree of probability which can be achieved through the usual means for target extraction from position-finding criteria; whereby there is obtained a still further increase in the effectiveness in that the searching or tracking surface of each projectile can be noticeably increased, inasmuch as its attacking mechanism will no longer be deflected by individual dummy targets present therein, and since through the thereby given overlapping of the searching or tracking surfaces, a plurality of parallel approaching projectiles can avoid their concentration on a single real target through different input data of the number of separating points of the real target series.
BRIEF DESCRIPTION OF THE DRAWING
Additional modifications and embodiments, as well as further features and advantages of the invention, can be ascertained from the following detailed description of an actual example for the utilization of the inventive method, as shown generally schematically in the single FIGURE of the drawing, in which there are illustrated mutually displaced projectiles approaching a target area with a typical distribution of real and false targets in a searching or tracking surface bounded within the target area.
DETAILED DESCRIPTION
The projectiles 10.1, 10.2 which are illustrated in the lower portion of the drawing are fired, for example, in a fan or spread pattern in the direction towards a target area 11, in which there have been discovered or there are presumed to be targets 12 which are to be attacked. Preferably, the foregoing relates to projectiles 10 which in the final phase of flight are self-controlled and target-seeking. In every instance are the projectiles 10 equipped with sensors 13 which, sloping forwardly, angled relative to the current direction of flight 14 towards the target area 11, scan a searching or tracking surface 15, in order to determine, by means of active or passive position-finding techniques, target criteria from the searching surface 15. On board of the projectiles 10, this information received from the searching surface 15 is processed, for instance, pursuant to the rule of mathematical statistics (in effect, by means of correlation techniques) in order to distinguish real or genuine targets 12 from apparently dummy-like false target 16. However, in actual practice, it must also be taken into calculation that at least few of the false targets 16, because of their geometry, their radiation characteristics or similar criteria are not clearly distinguishable from the genuine targets 12 which are alone of interest. Within the searching surface 15, at realistic data processing demands on the projectiles 10, besides the genuine or real targets 12 contained therein, there are also detected false targets 16 (but no longer distinguishable on the basis of their target criteria), the attacking of which would not be worthwhile; in effect, would not add to the effectiveness of the technological combat applications of the projectiles 10. This effectiveness becomes poorer when the searching surface 15 is increased relative to the respective projectile 10, inasmuch as the number of the false targets 16 which can no longer be distinguished as such is increased thereby, whereas, on the other hand, upon a reduction in size of such a searching surface 15, there is encountered the danger that the real targets 12, which are located along its boundaries will drop out of the searching surface and can no longer be attacked at all by the projectile 10. In accordance with the type of constructive equipment conditions of a projectile 10 and the expected terrain and target conditions within the target area 11, through the use of mathematical models there can thus be calculated an optimized searching surface 15 and thereby the statistical effectiveness of the utilization of projectiles 10.
The projectiles 10 which are considered herein, or other target-seeking ammunition articles which come into consideration as spread-fired ammunition, are usually not employed against individual targets, but at locations wherein, in the target area 11, there is given or expected a collection of real or genuine targets 12 which are to be attacked. This will provide the result that, after the real or genuine target extraction within the searching surface 15 there will be locally encountered a target collection which relates for the largest part to real targets 12; in effect, at most with a few singly false targets 16 dispersed therein. The remaining information over a target which is singly dispersed over the remaining area of the searching surface 15 is thereby associated, with the greatest probability, not with real but with false targets 16, which in the interest of the effectiveness of the utilization of the projectiles 10 are not considered during their search for targets, and should thus not be attacked. For this purpose, the target homing arrangement in the projectile 10 is designed for the purpose that every target location 12/16 still remaining after the target extraction in the searching surface 15, has a target surrounding 17 searched for the presence of a relatively closely neighboring further target location 12/16. In the event that within a target surrounding 17 there cannot be located any further target location 12/16, then this target 16 is interpreted as being "false" and will be ignored during homing onto a target. However, in the event that there is determined within the target surrounding 17 the presence of (at least) one further target location 12/16, under the displacement of the flight trajectory 14, a search is conducted in and about the target surrounding 17 for further target locations 12/16. Thus, when there is detected a series of positions of target points 12-12-16-12-12--within the searching surface 15, which are relatively closely neighboring to each other and thereby, with a great degree of probability, and in any event are overwhelmingly associated with real or genuine targets 12. An attack on one of these locations in a series of target points 18 thus leads with the greatest probability to the disabling of a real target 12 and, as a result, to the effective employment of the projectile 10; in essence, the effectiveness of the utilization of the projectile 10 is quite significantly increased thereby such that, notwithstanding reaching of the limits of target extraction through position-finding techniques, the false targets 16 which are still detected within the searching surface 15 can be ignored, insofar as by chance they do not lie in close proximity to a collection of real targets 12.
The radius 19 of the target surroundings 17 for the search after a series of target points 18 is again optimizable in accordance with the measure of the terrain conditions in the target area 11 and the type of the targets 12 which are to be attacked and their expected distribution, pursuant to the rules of probability computations, in order to ensure that for a typical distribution of real targets 12, the series of target points 18 will not terminate prematurely, but will extend over as many real targets 12 as possible; whereas on the other hand, with excessively large target surrounding 17 about the target points 12/16, false target 16 arranged therein can be introduced into the buildup of the series of target points 18, and thereby there can be interrupted the advance to a neighboring actual genuine target 12.
In the projectile 10, a switch to attack, in effect from the target searching phase to the homing onto a genuine target 12 which is to be attacked is only effected when the series of target points 18 can be set up through a pregiven number of support elements in the form of further target points 12/16 which are presently located in the target surroundings 17. It is simplest in the signal processing technology to attack the most recently detected target 12; in effect, the momentary final end point of the series of target points 18. Basically, however, there can be stored in a memory the position of a trailing support element of the series of target points, and the attack, while considering the path which has been traversed in the interim in the direction of flight 14, is then directed against this target 12.
Since for a fan or spread-like firing of a plurality of projectiles 10, their searching surfaces 15 can extensively overlap, and thereby a large collection of real targets 12 can be simultaneously evaluated in a plurality of projectiles 10 for presently one series of target points 18 as the attack criterium, this will lead to a noticeably greater increase in the effectiveness of the utilization of the projectiles 10, when the projectiles 10 which are fired almost simultaneously into the same region of the target area 11 are preset to the detection of a different number of target points 12/16 in the course of the formation of the series of target points 18. It is through the spatial and timewise displacement of the breakoff of the series of target points 18 that the probability increases that the different projectiles 10 will attack different real or genuine targets 12, thus avoiding an effectiveness-reducing multiple attack of projectiles 10 against one and the same, and possibly already destroyed target 12.
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A method for increasing the effectiveness of the utilization of target-seeking ammunition articles, which include a sensor scanning a predetermined searching surface within the target area for target criteria in order to suppress dummy targets during evaluation for steering towards or homing on the target. Upon the detection of a target within pregiven target surroundings, a search is conducted thereabout for a further target, and after detecting a predetermined number of such types of neighboring targets, one such target is approached.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
In modern society, a bathtub is becoming more frequently a walk-in bathtub having a hinged door and having a compressible door seal closing and sealing the door in a bather entryway through a side tub wall. The bather entryway is used by a bather to enter and exit the bathtub.
The present invention a walk-in bathtub adjustable door latch assembly employs a novel adjustably positionable closing lever to secure and to adjustably move and adjustably pressure a hinged door into a close sealing position in a bather entryway to guard against water leakage through the bather entryway.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to provide a walk-in bathtub adjustable door latch assembly incorporating a novel adjustably positionable closing lever to secure and to adjustably move and adjustably pressure a door into a close sealing watertight position in a bather entryway that passes through a side tub wall.
Another object is to provide a latch assembly having a closing lever that engages the edge of the hinged door before the door seal begins to compress and thus makes the door easier to close and secure by a bather limited to using one hand either by choice or disability.
A further object is to provide easy and simple adjustment of the closing lever that is integral with the structure that incorporates the lever into the door latch assembly.
A further object is to provide a rugged and durable latch assembly that is aesthetically pleasing to a bather.
The present invention incorporates a secure, uncomplicated relatively unbreakable and inexpensively produced closing lever and thereby provides an improved door latch assembly.
Additional and various other objects and advantages attained by the invention will become more apparent as the specification is read and the accompanying figures are reviewed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a perspective view of a walk-in bathtub having a hinged door;
FIG. 2 is a perspective partial view from above of the preferred embodiment of a walk-in bathtub adjustable door latch assembly in an intermediate position during closing and securing of a hinged door and showing an uncompressed door seal;
FIG. 3 is a perspective partial view from above of the preferred embodiment of a walk-in bathtub adjustable door latch assembly showing the hinged door and the latch assembly in a closed condition and showing a compressed door seal;
FIG. 4 is a top plan view of a base friction disc;
FIG. 5 is a top plan view of a slotted rotating disc;
FIG. 6 is a side view of a center post;
FIG. 7 is a top view of a slotted rotating disc assembly;
FIG. 8 is a cross-sectional view of the slotted rotating disc assembly as viewed in direction 8 - 8 in FIG. 7 ;
FIG. 9 is a top plan view of a top friction disc;
FIG. 10 is a side view of a closing lever (ball end not shown);
FIG. 11 is an exploded perspective view of the door latch assembly of the preferred embodiment (escutcheon not shown);
FIG. 12 is a perspective view of the door latch assembly of the preferred embodiment (escutcheon not shown);
FIG. 13 is a side view of the door latch assembly showing the closing lever in a closed position showing a maximum closure position of a bowed portion of the closing lever and showing the closing lever in an alternative open position (ball end not shown);
FIG. 14 is a perspective partial view from above and inside the bathtub of the preferred embodiment of a walk-in bathtub adjustable door latch assembly in an open position, showing an alternative closed position (escutcheon not shown), showing an arrow A that indicates a movement arc of the closing lever, showing a dashed line B that indicates an arc of path of contact point of a middle bowed portion of the closing lever on a lever contact strike plate, and showing the hinged door ajar; and
FIG. 15 is a perspective partial view from above and inside the bathtub of the preferred embodiment of a walk-in bathtub adjustable door latch assembly in a closed condition (escutcheon not shown) and showing the hinged door in a closed position.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 through 15 , the present invention is a novel walk-in bathtub adjustable door latch assembly 20 .
FIG. 1 shows a walk-in bathtub 2 preferably made of molded fiberglass reinforced plastic having a bathtub side wall 4 . The side wall 4 has a bather entryway 8 that allows a bather to enter and exit the bathtub 2 . An inwardly swinging entryway hinged door 10 has a hinge 11 that mounts the door in the bather entryway 8 . An entryway door seal 12 is attached along portions of the door 10 that are interstitially positioned and compressed between the door and the edges of the bather entryway 8 during closing and sealing of the door in the entryway.
FIG. 2 shows an inward facing door surface 14 of the hinged door 10 that faces towards the interior of the bathtub and shows a portion of the uncompressed door seal 12 interstitially between a swinging end 16 of the door (away from the hinge) and a portion of the entryway 8 . FIG. 2 , further shows the door latch assembly 20 attached to an inward facing surface 6 of a bathtub sidewall near an inner opening side edge 18 of the entryway 8 , shows the latch assembly in an intermediate position during closing and securing of the door 10 , and shows a middle portion 74 of the latch assembly in contact with a lever contact strike plate 86 . Preferably, the strike plate 86 is made of high density polyethylene plastic and is attached to the inward facing door surface 14 and along the edge of the door nearest the latch assembly to cooperate with the middle bowed portion 74 .
FIG. 3 shows the door 10 in a closed position with the latch assembly 20 pressuring and securing the door in the closed position and compressing the door seal 12 . Preferably, the door seal 12 is a silicone bulb seal.
FIG. 4 shows a base friction disc 22 preferably made of 360 brass alloy and having three angularly and radially spaced transverse base friction disc mounting bores 24 . Each base friction disc mounting bore 24 may have a base friction disc counterbore 26 .
FIG. 5 shows a slotted rotating disc 32 that in the latch assembly 20 is rotatably centered on the base friction disc 22 (see FIG. 11 ), the slotted rotating disc preferably is made of stainless steel, is sized to overlay the base friction disc, and has three angularly and radially spaced equal radius slots 34 sized and located to cooperate with the base friction disc mounting bores 24 and sized to receive and slidingly retain three spacer bushings 54 respectively with one bushing within each slot. Preferably, a center post mounting bore 36 is transverse through the slotted rotating disc 32 at its center.
FIG. 6 shows a center post 40 preferably made of stainless steel having a free end 42 and a mounting end 44 with the mounting end preferably having a mounting nub 46 . The center post 40 has a transverse lever bore 48 near its free end 42 , and a set screw receiving bore 50 intersecting said lever bore 48 near its midlength.
FIG. 7 shows a top view of a slotted rotating disc assembly 30 comprising the slotted rotating disc 32 and the center post 40 .
As best seen in FIG. 8 , the center post 40 at its mounting end 44 is fixed perpendicularly to the center of the slotted rotating disc 32 preferably by welding. In the disc assembly 30 , the center post 40 has a transverse lever bore 48 spaced from and parallel to the slotted rotating disc 32 . Preferably, the mounting nub 46 is sized to fit within the center post mounting bore 36 of the slotted rotating disc 32 to facilitate the fixing of the center post 40 to the slotted rotating disc. In the assembled latch assembly 20 , a set screw 52 is removably fixed in the set screw receiving bore 50 .
As best seen in FIG. 11 , three spacer bushings 54 are sized to slidingly fit and be retained respectively with one said bushing within each slot 34 .
FIG. 9 shows a top friction disc 60 preferably made of 360 brass alloy having a center post receiving bore 62 at its center sized to closely and rotatably receive the center post 40 during assembly of the latch assembly 20 . The top friction disc 60 has three angularly and radially spaced transverse top friction disc mounting bores 64 , said top friction disc is sized to overlay the slotted rotating disc 32 , and the top friction disc mounting bores in the assembled latch assembly 20 are coaxial respectively to the base friction disc mounting bores 24 . Each top friction disc mounting bore 64 may have a top friction disc upper counterbore 66 .
FIG. 10 shows a closing lever 70 . Preferably, the closing lever 70 has a first straight portion 72 transitioning into a middle bowed portion 74 and the middle bowed portion transitioning into a free straight portion 76 and preferably the first straight portion has an annular set screw receiving groove 78 located near the midlength of the first portion. During assembly of the latch assembly 20 , the lever 70 is rotatably and adjustably mounted in the lever bore 48 (see FIGS. 2 , 3 , and 11 to 15 ).
FIG. 11 is an exploded view of the components of the latch assembly 20 of the preferred embodiment. During assembly of the latch assembly 20 , three mounting screws 82 are inserted and retained respectively with one said screw through each top friction disc mounting bore 64 , each spacer bushing 54 , each slot 34 , and each base friction disc mounting bore 24 .
FIG. 12 shows an assembled latch assembly 20 , shows the center post 40 received in said center post receiving bore 62 , and shows a ball end 80 attached to the free straight portion 76 at its free end.
In the preferred embodiment of the latch assembly 20 , the longitudinal axis of the first straight portion 72 and the longitudinal axis of the free straight portion 76 are coaxial. FIG. 13 shows with an double ended arrow marked on the end of the free straight portion 76 how the closing lever 70 can be rotated around the longitudinal axis of the first straight portion 74 to vary the lateral distance of the contact point of the middle bowed portion 74 relative to the lever contact strike plate 86 , shows a position of maximum displacement of the lever contact strike plate, and shows an alternative position of the closing lever.
The mounting screws 82 are used to attach the latch assembly 20 to the inward facing surface 6 of a bathtub side wall (as best seen in FIGS. 14 and 15 ) adjacent to the bather entryway 8 and the latch assembly positioned to cooperatively interact with a swinging end 16 of an inwardly swinging entryway hinged door 10 .
Preferably, in the assembled latch assembly 20 , the spacer bushings 54 are retained within the slots 34 of the slotted rotating disc 32 and sized to space the base friction disc 22 from the top friction disc 60 and thereby limit the amount of tension that can be applied to the slotted rotating disc by the mounting screws 82 and thereby allowing the slotted disc assembly 30 to rotate between the friction discs 22 and 60 .
FIGS. 2 , 3 , and 13 show an escutcheon 84 having an escutcheon center bore mounted over and concealing the base friction disc 22 , the slotted disc assembly 30 , the spacer bushings 54 , and the mounting screws 82 .
Preferably the spacer bushings 54 are made from stainless steel tubing. Preferably, the slotted rotating disc 32 , the center post 40 , the closing lever 70 , the set screw 52 , the mounting screws 82 , and the escutcheon 84 are made from stainless steel.
Alternatively, the middle bowed portion can comprise a descending segment having a longitudinal axis angling obliquely away from the longitudinal axis of said first straight portion, said descending segment transitioning into a zone of maximum lateral displacement away from the longitudinal axis of said first straight portion, and said zone transitioning into an ascending segment having a longitudinal axis angling obliquely back towards the longitudinal axis of said first straight portion.
Alternatively, the middle bowed portion can comprise a curved portion that first curves away from the longitudinal axis of said first straight portion and then curves back towards the longitudinal axis of said first straight portion.
Alternatively, the first straight portion may have an annular set screw receiving groove located near the free end of the first straight portion.
The preceding description and exposition of the invention is presented for purposes of illustration and enabling disclosure. It is neither intended to be exhaustive nor to limit the invention to the precise forms disclosed. Modifications or variations in the invention in light of the above teachings that are obvious to one of ordinary skill in the art are considered within the scope of the invention as determined by the appended claims when interpreted to the breath to which they fairly, legitimately and equitably are entitled.
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A walk-in bathtub adjustable door latch assembly incorporates an adjustably positionable closing lever to secure and to adjustably move and adjustably pressure a hinged door of a walk-in bathtub into a close sealing position in a bather entryway to guard against water leakage through the bather entryway.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a fitness function analysis system and an analysis method thereof, and more particularly to a fitness function analysis system and an analysis method thereof capable of achieving a prediction analysis effectively.
[0003] 2. Description of Related Art
[0004] As global economy and stock market grow rapidly in recent years, stock price prediction becomes an important subject for both companies and individuals. As to companies, an accurate stock price prediction is applied to banks, stocks and securities, or venture capitals for a more efficient investment plan to create higher profit. As to individual investors, the accurate stock price prediction can provide a stock price trend and lower the risk of investments.
[0005] In addition to the technical analysis and basic analysis, conventional stock price predictions adopt the popular neural network prediction model, and researches indicated that the use of the neural network as the stock price prediction model has a relatively accurate prediction performance. However, the application of neural networks on the stock price prediction is very limited due to the lack of comprehensive network architectures and parameter selection mechanisms, such that the practical applicability of the stock price prediction is lowered.
[0006] Since many factors affect the stock price and correlations exist among variables, therefore selection used as a parameter of the neural network model becomes an influential factor of a stock price and the most important index of an accurate predicted stock price. For example, if there is no specific method for the decision of hidden layers of interactions among inputted parameters of a recurrent neural network. If too many parameters are used in the hidden layer of a complicated model, the network will lack of the ability of mathematical induction. If too few parameters are used in the hidden layer, the network will be unable to obtain an accurate prediction result. Such conventional prediction method always gives a prediction result with an error, and thus a design of a fitness function analysis system and an analysis method thereof is an important subject that demands immediate attentions and feasible solutions.
SUMMARY OF THE INVENTION
[0007] In view of the problems of the prior art, it is a primary objective of the present invention to provide a fitness function analysis system and an analysis method thereof to overcome the problems of the conventional prediction methods having too many complicated parameters that cause a complicated prediction and an inaccurate prediction result.
[0008] To achieve the foregoing objective, the present invention provides a fitness function analysis system comprising: an initializing module, a searching module, a calculating module and a processing module. The initializing module initializes a plurality of reference solutions. The searching module is coupled to the initializing module for finding an adjacent reference solution and an adjacent fitness function within a range with a distance from each fitness function according to a fitness function of each of the reference solutions. When the adjacent fitness function within the range of one of the fitness functions is greater than the fitness function, the searching module will replace the fitness function by the adjacent fitness function, such that the adjacent fitness function becomes a new the fitness function. The calculating module is coupled to the searching module for calculating the proportion of any one of the fitness functions in the summation of the plurality of fitness functions. The processing module is coupled to the initializing module, the searching module and the calculating module, such that if the number of times for the searching module finds the adjacent reference solution and the adjacent fitness function within a range with a distance from one of the fitness functions exceeds a threshold, but still no adjacent fitness function greater than one of the fitness functions is found, then the processing module will generate another fitness function corresponding to one of the fitness functions.
[0009] To achieve the foregoing objective, the present invention further provides a fitness function analysis method comprising the steps of: initializing a plurality of reference solutions by an initializing module; finding an adjacent reference solution and an adjacent fitness function within a range with a distance from each fitness function by a searching module, according to a fitness function of each of the reference solutions; replacing the fitness function by the adjacent fitness function by the searching module, if the adjacent fitness function within the range of one of the fitness functions is greater than the fitness function, such that the adjacent fitness function becomes a new fitness function; calculating the proportion of any one of the fitness functions in the summation of the plurality of fitness functions by a calculating module; and generating another fitness function corresponding to one of the fitness functions by a processing module, if the number of times for the searching module finds the adjacent reference solution and the adjacent fitness function within a range with a distance from one of the fitness functions exceeds a threshold, but still finding no adjacent fitness function greater than one of the fitness functions.
[0010] Wherein, the processing module replaces one of the fitness functions by the other fitness function if the processing module determines that the other fitness function is greater than one of the fitness functions, such that the other fitness function becomes a new fitness function.
[0011] Wherein, each of the reference solutions is a multi-dimensional vector, and the dimension of the multi-dimensional vector is equal to the number of optimal parameters.
[0012] Wherein, the threshold is equal to the number of the plurality of reference solutions multiplied by the dimension of the multi-dimensional vector.
[0013] Wherein, the processing module controls the searching module and the calculating module to stop each searching and processing after the processing module has received a stop signal.
[0014] Wherein, the processing module randomly generates the other fitness function corresponding to one of the fitness functions.
[0015] In summation, the fitness function analysis system and analysis method of the present invention have one or more of the following advantages:
[0016] (1) The fitness function analysis system and analysis method in accordance with the present invention can optimize the weighted value and error of the recursive neural network in the design of a parametric space. In other words, the invention uses the neural network as a base in conjunction with the parameter optimization and algorithm development to reduce the prediction error, so as to enhance the ability of predicting the stock price.
[0017] (2) The fitness function analysis system and analysis method in accordance with the present invention can optimize the weighted value and error of the recursive neural network in the design of a parametric space. In other words, the invention uses the neural network as a base in conjunction with the parameter optimization and algorithm development to reduce the prediction error, and the invention is used in many prediction areas, such as the prediction of an electric bill of the coming day.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a block diagram of a fitness function analysis system in accordance with a preferred embodiment of the present invention;
[0019] FIG. 2 is a schematic diagram of a recursive neural network in accordance with a preferred embodiment of the present invention; and
[0020] FIG. 3 is a flow chart of a fitness function analysis method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The relative variable selection system and selection method thereof in accordance with the present invention will become apparent with the detailed description of preferred embodiments together with related drawings as follows. It is noteworthy to point out that same numerals are used for representing respective elements in the description of the preferred embodiments and the illustration of the drawings.
[0022] With reference to FIG. 1 for a block diagram of a fitness function analysis system in accordance with a preferred embodiment of the present invention, the fitness function analysis system 1 comprises an initializing module 10 , a searching module 11 , a calculating module 12 and a processing module 13 . The initializing module 10 initializes reference solutions of a plurality of multi-dimensional vectors, wherein the dimension of the multi-dimensional vector is the number of optimal parameters. The searching module 11 is coupled to the initializing module 10 for finding an adjacent reference solution and an adjacent fitness function within a range with a distance from each fitness function according to a fitness function of each of the reference solutions. If the adjacent fitness function in the range of one of the fitness functions is greater than the fitness function, the searching module 11 will replace the fitness function by the adjacent fitness function, such that the adjacent fitness function becomes a new fitness function. The calculating module 12 is coupled to the searching module 11 for calculating the proportion of any one of the fitness functions in the summation of the plurality of fitness functions.
[0023] The processing module 13 is coupled to the initializing module 10 , searching module 11 and calculating module 12 . If the number of times for the searching module 11 finding the adjacent reference solution and the adjacent fitness function in a range with a distance from one of the fitness functions exceeds a threshold and no adjacent fitness function greater than one of the fitness functions is found, the processing module 13 will randomly generate another fitness function corresponding to one of the fitness functions. Wherein, the threshold is equal to the number of the plurality of reference solutions multiplied by the dimension of the multi-dimensional vector. If the processing module 13 determines that the other fitness function is greater than one of the fitness functions, the processing module 13 will replace one of the fitness functions by the other fitness function, such that the other fitness function becomes a new fitness function. After the processing module 13 has received a stop signal, the processing module 13 controls the searching module 11 and calculating module 12 to stop each searching and processing. The persons ordinarily skilled in the art should understand that the preferred embodiments are provided for illustrating the present invention, but not for limiting the invention. Any combination or separation of the aforementioned functional modules can be made depending on the required design.
[0024] In another embodiment, the recursive neural integration analysis system based on the bees algorithm is used for describing the fitness function analysis system and analysis method of the present invention.
[0025] Firstly, a fitness function analysis system adopts a selection method that uses a stepwise regression correlation selection (SRCS) to create the choice method of input factors. In this preferred embodiment, data including basic factors and technical factors are listed first. After the data are processed by a wavelet transform, the stepwise regression correlation selection can select the most influential factor.
[0026] Wherein, the operating method of the stepwise regression correlation selection is divided into the following stages: Firstly, candidate input factors are loaded into a receiving module, and then a correlation coefficient of each target dependent variable corresponding to each factor is determined, and the absolute values are sorted in a descending order by the correlation coefficients. The input factor with an absolute value of the correlation coefficient smaller than 0.4 is deleted, and the p value of each input factor is used for examining the significance of each factor to a target dependent variable to create a regression model of the target dependent variable.
[0027] By using the aforementioned method to select a plurality of factors, it is necessary to further use the F value of each factor to check whether the statistical significance exist. The F value is equal to a mean square regression divided by a mean square error as shown in the following equation:
[0000]
F
j
=
MSR
(
X
j
X
1
,
…
,
X
j
-
1
,
X
j
+
1
,
…
,
X
k
)
MSE
(
X
1
,
…
,
X
k
)
(
1
)
F
j
*
=
Max
1
≤
j
≤
k
(
F
j
)
(
2
)
[0028] If the F value of a certain factor is smaller than a user-defined threshold, then the factor will not have the statistical significance and will be deleted. If each factor in the regression model examined by the aforementioned method has the statistical significance, then the stepwise regression correlation selection will be terminated.
[0029] It is noteworthy to point out that when the stepwise regression correlation selection method is used for selecting important factors, each factor corresponding to the dependent variable must have substantial significance. In this example, the level of significance is set to 0.001. If the p value of a specific variable is smaller than 0.001, the variable is considered as a significant factor and will be added into the regression model. If the p value of a specific variable is greater than 0.001, the variable is considered as a non-significant factor and will be deleted from the regression model.
[0030] For the F value, the threshold of this example is set to 4. If the F value of a specific variable is greater than 4, then the variable is considered as a significant factor and will be added into the regression model. If the F value of a specific variable is smaller than 4, then the variable is considered as a non-significant factor and will be deleted from the regression model.
[0031] With reference to FIG. 2 for a schematic diagram of a recursive neural network in accordance with a preferred embodiment of the present invention, the advantage of using the recursive neural network is its ability of performing complicated computations and learning a temporal series mode such as a time-variant series. The recursive neural network of this preferred embodiment includes four major portions, respectively: an input layer, a hidden layer, a collection layer and an output layer. Wherein, each hidden neuron is connected to its own or other neuron and each connection have its weighted value and deviation value. The bees algorithm can be used for computing the neural network training process to find the weighted value (w) of each connection between the input layer, hidden layer and output layer and the deviation value (b) of each hidden layer and output layer. In FIG. 2 , the input layers are numbered with 21 , 22 , 23 , 24 , and 25 , the hidden layers are numbered with 26 , 27 , 28 , and the output layers is number with 29 . The numeral 30 stands for the weighted value w 61 of the portion connected from the input layer 21 to the hidden layer 26 , and the numeral 31 stands for the weighted value w 98 of the portion connected from the hidden layer 28 to the output layer 29 . The weighted values of the connected input layer, hidden layer and output layer can be derived. In addition, the hidden layers 26 , 27 , 28 , and the output layer 29 have the deviation values b 26 , b 27 , b 28 , and b 29 .
[0032] The bees algorithm is a basic recursive algorithm of a group, and the group intelligent behavior of a bee's searching for food can be used for developing an optimization algorithm for searching a food source with the largest amount of nectar. The bees algorithm primarily involve three kinds of bees including the worker bee, patrol bee and scout bee in a colony of bees, and each food source represents a possible solution corresponding to the studied problem, and the quantity of food sources is equal to the number of solutions.
[0033] In this preferred embodiment, a number (SN) of initial solutions will be created randomly when the algorithm starts, wherein SN stands for the number of worker bees or patrol bees. The number of worker bees is equal to the number of patrol bees, and each food source which is also the solution X h (h=1, 2, . . . , SN) stands for a one-dimensional vector d, and d is the optimal number of parameters required for the problem. In the entire bees algorithm, the process of finding the solution is limited by the setting of the maximum cycle number (MCN). The search will stop when the set MCN is reached.
[0034] After the random initial setting of the food source is completed, a worker bee is placed in an area of each food source, and then the amount of nectar in the food source where each worker bee is located (or the goodness of fit) will be evaluated, and the evaluation is carried out by the goodness of fit function (3) as follows:
[0000]
fit
i
=
{
1
f
i
+
1
,
f
i
≥
0
1
+
f
i
,
f
i
<
0
(
3
)
[0035] Wherein, f i is the i th solution (food source) of a target function in the problem, and then each worker bee evaluates the goodness of fit of the nearby food source from its own location. If the goodness of fit of the nearby food source is greater than the goodness of fit of the current position of the worker bee, then the worker bee will move to the new food source. The neighbor solution can be found by Equation (4):
[0000] S hj =X hj +u ( X hj −X kj ) (4)
[0036] Wherein, u is a uniform random variable of [−1, 1], X h =(X h1 , X h2 , . . . , X hd ) stands for the location of the current food source, S h stands for another food source near X h , and the difference between S h and X h resides on that S h =(X h1 , X h2 , . . . , X h(j−1) , S hj , X h(j+1) , . . . , X hd ). In other words, besides the element of the dimensional parameter j, both elements are equal, and the element situated at j is determined by Equation (4). The parameter j is a randomly selected integer in [1, d].
[0037] After the worker bee completes a nearby search, the worker bee will send the final obtained information of the food source to the patrol bee, and the patrol bee starts evaluating the goodness of fit of the nearby food source from the position of the patrol bee. If the goodness of fit of the nearby food source is greater than that of current one, then the patrol bee will shift to the new food source. Similarly, a neighbor solution of the best food source searched by the final worker bee can be found by Equation (2) and used for a further search. Finally, the patrol bee compares the goodness of fit of its own solution with the solution provided by the worker bee based on Equation (5).
[0000]
P
h
=
fit
h
∑
h
=
1
SN
fit
h
(
5
)
[0038] In Equation (5), the denominator includes the summation of the goodness of fit food of areas searched by patrol bees and provided by worker bees, which stands for the percentage of all possible solutions of the goodness of fit of each food source during the patrol stage, and then the food source with a higher goodness of fit is selected.
[0039] It is noteworthy to point out that if a solution processed through a number of tolerance loops as set in Equation (6) in a regression process still cannot generate a better food source, then such solution will be taken over by a scout bee, and a new solution will be generated through Equation (7). If the new solution has a higher goodness fit, then it will replace the previous solution, or else the previous solution will be kept.
[0000] limit= SN×d (6)
[0000] X h j =X min j +rand[ 0,1]( X max j −X min j ) (7)
[0040] Even though the concept of the fitness function analysis method for the fitness function analysis system of the present invention has been described in the section of the fitness function analysis system, a flow chart is used for illustrating the method as follows.
[0041] With reference to FIG. 3 for a flow chart of a fitness function analysis method of the present invention, the fitness function analysis method is applied to a fitness function analysis system, and the fitness function analysis system comprises an initializing module, a searching module, a calculating module and a processing module. The fitness function analysis method of the fitness function analysis system comprises the steps of:
[0042] (S 31 ) initializing a plurality of reference solutions by an initializing module;
[0043] (S 32 ) finding an adjacent reference solution and an adjacent fitness function within a range with a distance from each fitness function by a searching module according to a fitness function of each of the reference solutions;
[0044] (S 33 ) replacing the fitness function by the adjacent fitness function by the searching module if the adjacent fitness function within the range of one of the fitness functions is greater than the fitness function, such that the adjacent fitness function becomes a new fitness function;
[0045] (S 34 ) calculating the proportion of any one of the fitness functions in the summation of the plurality of fitness functions by a calculating module;
[0046] (S 35 ) generating another fitness function corresponding to one of the fitness functions by a processing module if the number of times for the searching module finds the adjacent reference solution and the adjacent fitness function within a range with a distance from one of the fitness functions exceeds a threshold, but no adjacent fitness function greater than one of the fitness functions is found;
[0047] (S 36 ) replacing one of the fitness functions by the other fitness function by the processing module if the processing module determines that the other fitness function is greater than one of the fitness functions, such that the other fitness function becomes a new fitness function; and
[0048] (S 37 ) controlling the searching module and the calculating module to stop each searching and processing by the processing module after the processing module has received a stop signal.
[0049] The details and implementation method of the fitness function analysis method for the fitness function analysis system of the present invention have been described in the aforementioned fitness function analysis system of the present invention, and thus will not be described here again.
[0050] In summation of the description above, the fitness function analysis system and analysis method in accordance with the present invention can optimize the weighted value and deviation values effectively in the design of a parametric space. In other words, the neural network is used as a base in conjunction with the parameter optimization and algorithm development to reduce the prediction error. The present invention can be applied in many prediction areas such as the prediction of a stock price or an electric bill of the coming day.
[0051] Exemplary embodiments have been disclosed herein, and although specific terms are employed, they are used and are to be interpreted in a generic and descriptive sense only and not for purpose of limitation. Accordingly, it will be understood by those of ordinary skill in the art that various changes in form and details may be made without departing from the spirit and scope of the present invention as set forth in the following claims.
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The present invention discloses a fitness function analysis system and an analysis method thereof. Wherein, an initializing module initiates a plurality of reference solutions. Based on fitness functions of reference solutions, a searching module searches a fitness function adjacent to the fitness functions. While an adjacent fitness function close to the fitness function is greater than the fitness function, the searching module replaces the fitness function by the adjacent fitness function. A calculating module calculates the proportion of any fitness function to the summation of the fitness functions. While the searching module counts the number of times that the searching module has searched an adjacent function close to the fitness function, the number of times exceeds a threshold value, and there is no adjacent fitness function greater than the fitness function, a processing module will generate another fitness function corresponding to the fitness function and compare the two fitness functions.
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TECHNICAL FIELD
[0001] The present invention generally relates to motor vehicle powertrain control, and more particularly relates to a control module communicating with a motor vehicle powertrain having coded engine control states.
BACKGROUND
[0002] Power take-off (PTO) may be a common function used in vehicle powertrain management. PTO may provide power to up-fitter installed accessories such as a bucket lift, also referred to as a “cherry picker”, a snow plow, a dump body, etc. PTO is a mechanism or technique, such as using a gearbox or bolt-on attachment, of driving a pump to supply power necessary to provide a function, such as lifting or manipulating the dump body, bucket lift, or snow plow. PTO may be enabled through conventional switching of a single polarity change, such as between an unasserted low, or inactive state, and an asserted high, or active state. Common switching arrangements for PTO enable function, Tap-up function, and Tap-down function include the use of 0 Volts for the unasserted low state and a battery voltage for the asserted high state for each of those functions.
[0003] A concern with control of engine operation is with failure modes of communication between various engine components. Compliance with probability of occurrence metrics is generally required to meet safety and performance requirements of various motor vehicle components. A rolling count or other similar failure checking mechanism is currently used to monitor PTO states, but these mechanisms generally require complex software operations. Additionally, failure modes of various conventional PTO states are generally undesirable operating states. For example, the single function switch for cruise enable and PTO enable, previously mentioned hereinabove, defaults to one of the unasserted low state or asserted high state to produce an undesirable condition.
[0004] Accordingly, it is desirable to provide an engine management system for motor vehicle powertrain applications that has improved failure modes. In addition, it is desirable to provide a control module that communicates with the vehicle powertrain that is simple to implement, accepts multiple input options, and accounts for a variety of communication errors. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
BRIEF SUMMARY
[0005] According to various exemplary embodiments, an apparatus is provided for PTO related engine control having improved failure modes and communication with PCM or ECM independent of input architecture. In one exemplary embodiment, the apparatus is a control module for a vehicle powertrain having an input circuit receiving signals corresponding to a 4-bit code, and a processor connected to the input circuit and outputting a control signal corresponding to one of a plurality of 4-bit coded engine control states. The engine control states are coded such that potential errors in communication between the control module and powertrain, and their resulting effects on powertrain operation, are minimized. For example, a single bit change during communication does not result in a transition from one engine control state to another engine control state.
[0006] In another exemplary embodiment, the apparatus is a communication device for motor vehicle powertrain control having: a switching circuit with at least three outputs for transmitting switch signals corresponding to an engine request; and, a detector circuit having an input receiving switch signals from the switching circuit. In this embodiment, the detector circuit transmits an output signal upon determination of a four-bit coded function state corresponding to the received switch signals. The function states are selected from a No Action state, a PTO Off state, a PTO On state, a Reserved state, a Speed Up state, a Speed Down state, one of a Speed Up Fast state and a Failed Action state, and one of a Speed Down Fast state and an Indeterminate state.
[0007] In yet another exemplary embodiment, an electronic engine management system is provided having an engine control module (ECM) varying engine function in a motor vehicle, and a PTO module connected to the ECM and transmitting control signals to the ECM. In this embodiment, the PTO module includes an input circuit receiving engine request signals, and a processor connected to the input circuit and selecting a control signal from a plurality of four-bit coded engine control states based on the received engine request signals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and
[0009] FIG. 1 is a block diagram of an exemplary vehicle.
DETAILED DESCRIPTION
[0010] The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the drawings.
[0011] According to various embodiments, a control module is provided that communicates engine or vehicle powertrain requests to conventional powertrain control modules (PCM) or engine control modules (ECM). The requests may be correspond to any variety of engine control states including, but not limited to, power take-off (PTO) enable or PTO On, PTO disable or PTO Off, vehicle speed set 1, speed-up engine speed, vehicle speed set 2, speed-down engine speed, speed-up engine speed fast, speed-down engine speed fast, no action, failed action, indeterminate. A number of different input architectures may be used with the control module such as five (5) position PTO internal cab switches, seven (7) position PTO internal cab switches, and multiple three-state PTO switches. Other single position or multiple position switch inputs may be connected with the control module depending on desired engine control operations. Using four-bit coded engine control states, the control module may transmit engine control states to the PCM with improved failure modes, described in greater detail hereinbelow.
[0012] Although the present invention is described in the context of engine control states and related communication between the PTO control module and PCM, other engine requests or vehicle operation requests or states may be similarly communicated between a control module and an appropriate vehicle component. For example, a control module may be connected with an electronic door lock having multiple function positions, such as door lock, power on, ignition on, windows up, and door unlock. In this example, the control module may be connected to multiple vehicle components and transmit operation states or requests to each component based on a desired function request.
[0013] Referring to the drawings, FIG. 1 is a block diagram of an exemplary vehicle, shown generally at 10 , having a PTO control module 12 communicating engine control states to a PCM 14 . A switch input 16 is connected to the control module 12 to convey input signals corresponding to user-desired or user-initiated engine operation requests. The switch input 16 may take a variety of different structures as previously mentioned, and the control module 12 is well-suited to operate with switches having multiple inputs to the control module 12 . The control module 12 may optionally be connected to multiple vehicle components 14 , 15 depending on the desired vehicle operation requests. It should be appreciated that the blocks of FIG. 1 (as well as the blocks in the other block diagrams disclosed herein) can represent functional elements and discrete hardware elements. For example, in one embodiment of the invention, some of the functions or hardware elements illustrated in FIG. 1 may be implemented in a single processor unit. Alternatively, a portion of the functions may be implemented in a single processor unit in combination with hardware elements. The functions can be implemented in hardware, all in software, or a combination of hardware and software can be used.
[0014] The PTO control module 12 receives input signals 16 , 18 , 20 from the PTO function switch 16 and transmits a control signal 32 to the PCM 14 based on the received signals 17 , 18 , 20 . The received input signals 17 , 18 , 20 correspond to four-bit coded engine control states where each desired engine control state is assigned a unique four-bit code. Any remaining four-bit codes that have not been assigned to a desired engine control state are each set as a failure state. In one embodiment, the PTO control module 12 is a microprocessor-based controller having discrete inputs associated with the PTO function switch and memory storing a look-up table of engine control states corresponding to each four-bit code. In this embodiment, depending on the received input signals 17 , 18 , 20 , the PTO control module 12 determines a corresponding engine control state from the look-up table in memory and transmits such engine control state to the PCM 14 . The PTO control module 12 may communicate with the PCM 14 using a conventional high speed serial interlink, such as controller area network (CAN). In automotive applications where one-byte serial communication is commonly used, the four-bit coded states are compatible and also have an advantage of simplicity while providing a robust system.
[0015] The switch 16 is an electronic switch or switching circuit for a vehicle powertrain function, such as PTO, and may be based on multiple two-state or multi-state inputs to the control module 12 . For example, the switch may have a first input connected to one of two different reference voltages and a second input connected to one of the two reference voltages. One of the reference voltages may be a high reference voltage, such as a battery voltage (e.g., B + or V ref ), and the other reference voltage may be a low reference voltage, such as ground or 0 Volts. Those skilled in the art will appreciate that voltage divider circuits and analog-to-digital converters may optionally be included depending on input requirements of the control module 12 .
[0016] The switch 16 is any device capable of providing various output signals 16 , 18 , 20 such as logic high and logic low signals, to the control module 12 in response to user commands, sensor readings or other input stimuli. In an exemplary embodiment, the switch 12 responds to user selections made by displacing or activating a lever (not shown) or other actuator on the switch as appropriate. In another embodiment, the switch 16 responds to non-actuated input, such as a sensor reading. Various switches may be formulated with electrical, electronic, and/or mechanical actuators to produce appropriate output signals onto a wire or other electrical conductor joining the switch 16 and the control module 12 . These logic signals may be processed by the control module 12 to place the component into desired states as appropriate.
[0017] Based on a pre-determined forward position look-up table of function states corresponding to the switch input signals 17 , 18 , 20 , the control module 12 determines and transmits an appropriate control signal 22 to the PCM 14 . The switch input signals 17 , 18 , 20 are translated by the control module 12 into four-bit coded function states. The assignment of different four-bit codes to a particular function state is such that a single bit change does not result in a transition from one function state to another function state. This single bit failure mode generally provides for more robust communication of function states or engine control states. Additional function state coding, described hereinbelow, further assists in providing robust communication.
[0018] Table 1 shows a variety of engine control states or function states corresponding to various combinations of signals received by the PTO control module 12 in one embodiment. In this embodiment, the PTO function states are 4-bit coded states and include a No Action state, a PTO Off state, a PTO On state, a Reserved state, a Speed Up state, a Set 1 speed or a Speed Up state, a Set 2 speed of a Speed Down state, a Speed Up Fast state or a Failed Action state, and a Speed Down Fast state or an Indeterminate state. The remaining four-bit codes that have not been assigned a function state are each a Failure state. The PTO Off state disables PTO. The PTO On state enables PTO. The Reserved state is not designated a particular function nor is it a Failure state. In one embodiment, the Speed Up state requests powertrain operation corresponding to increase vehicle engine speed, and the Speed Down state requests powertrain operation corresponding to decrease vehicle engine speed. In another embodiment, the Set 1 state requests powertrain operation corresponding to establishing a first speed of the vehicle, and the Set 2 state requests powertrain operation corresponding to establishing a second speed of the vehicle. In one embodiment, the Speed Up Fast state requests powertrain operation corresponding to a larger step or higher rate of increased vehicle engine speed, and the Speed Down Fast state requests powertrain operation corresponding to a larger step or higher rate of decrease vehicle engine speed. In another embodiment, the Failed Action state indicates a problem with at least one input and the PCM does not act on the request. In another embodiment, the Indeterminate state is a pre-transmission state, such as for contact bounce or prior to hardware (e.g., microprocessor) initialization.
[0019] The Speed Up state is a 4-bit complement of the No Action state, and the Speed Down state is a 4-bit complement of the Reserved state. The Speed Up Fast state or Failed Action state is a 4-bit complement of the PTO Off state, and the Speed Down Fast state or Indeterminate state is a 4-bit complement of the PTO On state. The PTO Off state and PTO On state are coded such that the respective complement does not result in a transition between these states. Each of these coding constraints provides communication failure modes that are generally desirable from an engine management standpoint.
TABLE 1 Decimal Bit 4 Bit 3 Bit 2 Bit 1 Value Function State 0 1 1 0 6 No Action 0 0 0 0 0 PTO OFF 0 0 1 1 3 PTO ON 0 1 0 1 5 Reserved 1 0 0 1 9 Set 1 or Speed Up 1 0 1 0 10 Set 2 or Speed Down 1 1 0 0 12 Speed Up Fast or Failed Action 1 1 1 1 15 Speed Down Fast or Indeterminate
[0020] Table 2 shows a variety of engine control states or function states corresponding to various combinations of signals received by the PTO control module 12 in another embodiment. The PTO function states are also 4-bit coded states and include a No Action state, a PTO Off state, a PTO On state, a Reserved state, a Speed Up state, a Set 1 speed or a Speed Up state, a Set 2 speed of a Speed Down state, a Speed Up Fast state or a Failed Action state, and a Speed Down Fast state or an Indeterminate state. The Speed Up state has a 4-bit complement of the No Action state, and the Speed Down state has a 4-bit complement of the Reserved state. In this embodiment, the Speed Up Fast state has a 4-bit complement of the PTO On state, and the Speed Down Fast state has a 4-bit complement of the PTO Off state. The remaining four-bit codes that have not been assigned a function state are each a Failure state. These coding constraints also provide communication failure modes that are generally desirable from an engine management standpoint. In both Tables 1 and 2, a transition from one function state to another function state requires a two-bit error.
TABLE 2 Decimal Bit 4 Bit 3 Bit 2 Bit 1 Value Function State 0 0 0 1 1 No Action 0 0 1 0 2 PTO OFF 0 1 0 0 4 PTO ON 1 0 0 0 8 Reserved 1 1 1 0 14 Set 1 or Speed Up 0 1 1 1 11 Set 2 or Speed Down 1 1 0 1 13 Speed Up Fast or Failed Action 1 0 1 1 7 Speed Down Fast or Indeterminate
[0021] Table 3 shows an exemplary embodiment of the four-bit coding shown in Table 1 with an internal cab switch, stationary or mobile, providing three-state inputs to the PTO control module.
TABLE 3 Decimal Input 1 Input 2 Input 3 Value Function State V V V 6 No Action 0 V 1 0 PTO OFF 1 V 0 3 PTO ON Spare Spare Spare 5 Reserved V 0 1 9 Set 1 or Speed Up V 1 0 10 Set 2 or Speed Down 0 1 V 12 Speed Up Fast or Failed Action 1 0 V 15 Speed Down Fast or Indeterminate
[0022] Table 4 shows an exemplary embodiment of the four-bit coding shown in Table 1 with a stationary external cab switch providing three-state inputs to the PTO control module.
TABLE 4 Decimal Input 1 Input 2 Input 3 Input 4 Value Function State 0/V 1 N/A N/A 0 PTO OFF 1 0/V N/A N/A 3 PTO ON Spare Spare Spare Spare 5 Reserved N/A N/A V V 6 No Action N/A N/A 0 1 9 Set 1 or Speed Up N/A N/A 1 0 10 Set 2 or Speed Down N/A N/A N/A N/A 12 Speed Up Fast or Failed Action N/A N/A N/A N/A 15 Speed Down Fast or Indeterminate
[0023] Table 5 shows an exemplary embodiment of the four-bit coding shown in Table 2 with an internal cab switch, stationary or mobile, providing three-state inputs to the PTO control module.
TABLE 5 Decimal Input 1 Input 2 Input 3 Value Function State V V V 1 No Action 0 V 1 2 PTO OFF 1 V 0 4 PTO ON Spare Spare Spare 8 Reserved V 0 1 14 Set 1 or Speed Up V 1 0 11 Set 2 or Speed Down 0 1 V 13 Speed Up Fast or Failed Action 1 0 V 7 Speed Down Fast or Indeterminate
[0024] Table 6 shows an exemplary embodiment of the four-bit coding shown in Table 2 with a stationary external cab switch providing three-state inputs to the PTO control module.
TABLE 6 Decimal Input 1 Input 2 Input 3 Input 4 Value Function State 0/V 1 N/A N/A 2 PTO OFF 1 0/V N/A N/A 4 PTO ON Spare Spare Spare Spare 8 Reserved N/A N/A V V 1 No Action N/A N/A 0 1 14 Set 1 or Speed Up N/A N/A 1 0 11 Set 2 or Speed Down N/A N/A N/A N/A 13 Speed Up Fast or Failed Action N/A N/A N/A N/A 7 Speed Down Fast or Indeterminate
[0025] In Tables 3-6, “1” is a high value, “0” is a low value, and “V” is an intermediate value used with the three-state inputs for the respective switches. “0/V” indicates either a low value or an intermediate value can be used for the input signal. “N/A” indicates an input signal from the corresponding input is not available. “Spare” indicates a non-assigned input that is also a non-failure designation. As shown from Tables 3-6 where different four-bit coding for switches having 3 and 4 three-state inputs, multiple input options of PTO architecture are available for use with the control module. However, other input combinations may be used with the four-bit coding embodiments shown in Tables 1 and 2.
[0026] Between the four-bit coding embodiments shown in Tables 1 and 2, the four-bit coding embodiment of Table 2 is preferred because default states (e.g., 0000 and 1111) are not assigned to function states. With either four-bit coding embodiment, rolling count or other failure checking mechanism is generally no required for the PTO function states. This reduces software complexity that may be used in the PTO control module and PCM.
[0027] The PTO control module 12 may also redundantly calculate engine speed requests. For example, the PTO control module 12 may poll the PCM for information on the actual speed upon receipt of a switch input corresponding to a Set 1, or Speed Up, request or a Set 2, or Speed Down, request. A serial bus (not shown) may be connected between the PTO control module 12 and the PCM 14 for actual speed polling. The actual speed information is compared by the PTO control module with the engine speed request, based on the switch input, to determine the status of the powertrain with respect to the engine speed request. In one embodiment, if the powertrain is currently operating according to the request, the PTO control module does not transmit the respective engine speed request. This assists in meeting safety requirements for communication between the PTO control module and the PCM.
[0028] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention as set forth in the appended claims and the legal equivalents thereof.
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Apparatus are provided for PTO related engine control having improved failure modes and communication with PCM or ECM independent of input architecture. The apparatus includes a control module for a vehicle powertrain having an input circuit receiving signals corresponding to a four-bit code, and a processor connected to the input circuit and outputting a control signal corresponding to one of a plurality of four-bit coded engine control states. The engine control states are coded such that potential errors in communication between the control module and powertrain, and their resulting effects on powertrain operation, are minimized. For example, a single bit change during communication does not result in a transition from one engine control state to another engine control state.
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The present invention relates generally to a multi-level vehicle parking facility having coordinated audible signal and visual display means whereby persons parking therein have simple and coordinated means to remind them of the level upon which their vehicles are parked within the parking garage.
BACKGROUND OF THE INVENTION
In today's society, many cities have large multi-leveled, multi-directed self-parking facilities. A person parking a vehicle in such a facility, even after a short time, may find it difficult upon returning to the facility to locate the parked vehicle. Lettering, numbering, or color-coding levels of floors for parking garages, generally do not have enough personal meaning to the individual parking a vehicle as a reminder or to "jog" ones memory as to which level the vehicle is parked.
The present invention provides significant advantages over previous garage identification means consisting only of numbers, and/or letters and/or color combinations, by utilizing multi-faceted coding means capable of providing an easy and a special reminder of the vehicle's level. In its preferred form, the invention utilizes a different, distinctive and unique popular song played on each level of the garage and a visual display of the title, as well as colors and numbers, to help remind the parker of the level where the vehicle is parked. The fact that these well known popular songs have been heard many times and over many years, creates an indelible impression upon the parker and makes it a matter of quick recognition of the tune or song assigned to a respective level where the vehicle was parked.
To additionally facilitate coding, the present invention utilizes songs of or about distinctive cities, which not only are popular but are clearly recognizable to further remind and make the parker familiar with the level in which the vehicle is parked.
Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the preferred embodiment of the invention, from the claims, and from the accompanying drawings, in which like numerals are employed to designate like parts throughout the same.
BRIEF SUMMARY OF THE INVENTION
An improved vehicle parking facility comprising a garage with more than one level, on which for each level there is provided an audible emitting means and corresponding visual display means, to assist persons in recalling upon which level they have parked their vehicles. In a preferred form, a song is used as the audible signal, and the distinctive song may reference a widely recognized city. A listing guide of the songs of each respective level is located at the entrance level of the garage to assist vehicle parkers in remembering which level their vehicle is parked, and also may be located within the facility elevator, if one is provided.
BRIEF DESCRIPTION OF THE DRAWING
A fuller understanding of the foregoing will be had by reference to the accompanying drawing wherein FIG. 1 is a perspective and schematic view of an improved vehicle parking facility constructed in accordance with the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible of embodiment in many different forms, there is shown in the drawing and will herein be described in detail a preferred embodiment of the invention. The invention disclosed herein is equally applicable to many conventional parking identification and control systems besides the embodiment shown and described herein. It should be understood that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit and scope of the invention and/or claims to the embodiment illustrated.
Referring now to FIG. 1, the numeral 10 indicates generally a multi-level parking garage in which the present invention is provided. A passenger transport device 15, as shown in the preferred embodiment as an elevator or potentially a stairway, transports pedestrians to and from respective facility levels 21-29, on which vehicles are parked and to the main entrance/exit level 20 or ground floor.
Signs 30, 35, 40, 45, 50, 55, 60, 65 and 70 each depicting a color, level number and, in the preferred embodiment the name of a widely recognized geographical location, such as a city, are located at the vehicle drive-through portions of each respective level 21-29 of garage 10. At least one audible sound emitting device, such as loudspeakers 75, 80, 85, 90, 95, 100, 105, 110 and 115, for emitting a popular song or the like referring to the geographical area or city is located at each respective level 21-29 of garage 10, with each such loudspeaker playing a different popular song coordinated with the area or city.
An entrance/exit 120 from a passenger transport device 15 is located on each respective level 21-29 in garage 10. A respective floor level number, color, the geographical or city name, and corresponding popular song title, is indicated on signs 125, 130, 135, 140, 145, 150, 155, 160 and 165 located adjacent the entrance/exit for the passenger transport device 15. An indicating guide 170 is located at the entrance/exit level 20 identifying all numeric levels, respective colors, city names and corresponding popular songs of each the respective levels. A doorway 175 is provided for entrance and exit on foot to and from the garage 10.
The operation of the present invention is simply and effectively described as follows. Vehicles generally identified by the numeral 180, enter the parking garage 10 at entrance/exit level 20 and park in open spaces on one of the respective levels 21-29. As the vehicle parker drives through respective levels 21-29, he or she passes one or more signs 30, 35, 40, 45, 50, 55, 60, 65, and 70 indicating a color, numerical level and a city name. After the vehicle 180 is parked on a particular level, the vehicle parker walks on foot to an exit 120 to enter passenger transport device 15. While waiting for the passenger transport device 15 to arrive at that level, the vehicle parker, in addition to observing the signs, also hears the popular song referencing the city that corresponds to the level on which the vehicle has just been parked, via one of the sound emitting devices 75, 80, 85, 90, 95, 100, 105, 110 and 115. Additionally, signs 125, 130, 135, 140, 145, 150, 155, 160, and 165 positioned adjoining the passenger transport entrance/exit 120 signify the color, numerical level, city name and title of the popular song being played, to further remind the parker on which level the vehicle is parked.
The pedestrian is then transported via the passenger transport device 15 to entrance/exit level 20 and exiting through passenger transport exit 120 leaving garage 10 through doorway 175.
Upon returning to the garage 10 the vehicle parker retrieves his vehicle 180, by entering on foot at the entrance/exit level 20 through door 175 and if need be, examines master indicating guide 170 listing the numeric levels, respective colors and titles of the popular songs referring to the corresponding cities. The pedestrian enters the passenger transport device 15 and travels to the level 21-29 where the vehicle 180 is parked, aided by the recognition of the color, the numerical level, and the song referring to the city. Upon entering that level, the pedestrian should immediately recognize and be reassured by the popular song emanating from one of their sound emitting devices 75, 80, 85, 90, 95, 100, 105, 110 and 115, that he or she has selected the proper level in which the vehicle 180 is parked. The pedestrian then proceeds to the vehicle 180 and leaves garage 10 by driving through the lower levels and exit through entrance/exit level 20. Examples of city and related songs found satisfactory include: (1) San Francisco; (2) Meet me in St. Louis; and (3) My Kind of Town, Chicago . . . etc.
This improved parking identification means allows individuals to easily recall at which level their vehicle is parked and be reassured upon their return, that they have selected the proper level to retrieve their vehicle. This invention eliminates the need for vehicle parkers to search a large multi-level parking garage for their vehicles if they have forgotten where they have parked their vehicles. The present invention alleviates the immense difficulty in finding a vehicle parked in a large multi-leveled, multi-tiered parking garage by a readily recall invoking means for identifying each level in a parking garage system.
While the foregoing has presented specific embodiments of the present invention it is to be understood that these embodiments have been presented by way of example only. Other combinations, such as but not limited to, school songs and schools, flowers and colors or any combination of sight and audible related signals may also be utilized. It is expected that others will perceive differences which, while bearing from the foregoing, do not depart from the spirit and scope of the invention herein described and claimed.
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An improved multi-level vehicle parking facility including a device for emitting an audible sound, preferably a well known song, on each parking level, with a visual display specifically identifying the audible sound emitted on each such level. Each level has a different audible sound emitted thereon and is identified on the corresponding visual display to facilitate recall of that level to an individual parking a vehicle thereon. In a preferred embodiment, the song is that of a city or other geographical area and the sign identifies the city or area.
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TECHNICAL FIELD
This invention relates to a method and apparatus for finishing the edges of a textile product. More particularly, the invention measures, cuts, and stitches the edges of a textile product such as a washcloth.
BACKGROUND OF THE INVENTION
The finishing process for high quality textiles such as washcloths generally has been performed manually because of the attention to detail that is required. The edges of a washcloth must be sewn to prevent fraying and to produce a desirable and lasting product. The process is therefore labor-intensive and time-consuming.
In the manual finishing process, each individual washcloth is cut from a strip of material. The material, typically terry cloth, comes in a continuous strip with transverse borders or "cut lines" present in the fabric at equally spaced intervals along the length of the strip. The cut line is generally an area in the cloth without any terry loops or plush material that represents where each individual washcloth is to be cut from the strip.
After each washcloth is cut, an operator maneuvers the washcloth around a sewing head to stitch or over-edge the sides. A high amount of operator skill is required to produce a washcloth with four uniform sides because the dimensions of each side of the material can often vary. Rounded-corner washcloths are particularly difficult to finish because each corner of the washcloth must be rounded in a uniform fashion. UPC labels, cloth loop labels, or single-ply labels also may be added to the edges of the washcloth.
While attempts have been made to automate the washcloth finishing process, these attempts have not been successful with respect to quality control and with respect to production time because of the lack of uniformity in the material. For example, the center of the corner radius of a washcloth should be positioned to an accuracy of less than 0.060 to 0.100 inches. If the dimensions of the washcloth differ by more than this amount in either length or width, as is often the case, the corners will not be properly stitched and the labels will not be properly attached.
Attempts to automate the washcloth finishing process include U.S. Pat. No. 4,685,408 to Frye, disclosing the use of a plate to guide a pre-cut washcloth into a rotating sewing head. Frye, however, simply finishes each washcloth to a standard dimension and thus does not accommodate the dimensional variations of each washcloth. Further, Frye does not have the ability to change the center of rotation at the corners of the washcloth because of the mechanically-fixed rotation. Smaller washcloths generally need smaller corner radii. The use of a rotating sewing head is also disfavored by the industry because of the thrust and lateral loads that are created within the sewing head. The centrifugal forces imparted to the sewing head impair lubricant dispersal and the associated cooling effects such that high maintenance is required.
Other attempts to automate the washcloth finishing process include U.S. Pat. No. 5,018,462 to Brocklehurst. Brocklehurst discloses the maneuvering of a washcloth around a sewing head by the use of a rotating plate controlled by optical sensors. Rotation of the plate is activated by a sensor detecting a corner of the washcloth and continues until the next corner is detected. The desired position for the center of the radius of each corner, however, may not be the same for all four corners of the washcloth. Rather than accommodating the actual dimensions of the entire washcloth, the apparatus of Brocklehurst simply finishes each corner on same axis of rotation.
What is needed therefore is a means for accommodating nonuniform workpieces into an automated finishing system. Without this ability to adapt to the dimensions of each individual washcloth, even minor variations in the raw material can lead to an unsatisfactory product.
SUMMARY OF THE INVENTION
Stated generally, the invention comprises a method and apparatus for manufacturing a textile product from a continuous strip of material having a plurality of transverse borders positioned at equally spaced intervals so as to define a plurality of discrete panels. The apparatus includes pulling means for pulling the strip along a predetermined path. As the strip is advanced, detecting means determine the position of the transverse border for each of the panels. Straightening means straighten each of the transverse borders. Calculating means operatively associated with the detecting means and the pulling means then determine the length of each of the panels while measuring means determine the width. Cutting means then separate each of the panels from the strip based upon the detection of the transverse borders. After each panel is cut, maneuvering means disposed along a calculated path maneuver each of the panels through finishing means based upon the determination of the length and the width.
Specific embodiments of the invention include an apparatus that operates in sequential fashion to finish the edges of a washcloth. A continuous strip of terry cloth or similar material is fed into the apparatus. The material is straightened and then pulled along a predetermined path by a feed pull gripper. The position of the cut line on each individual washcloth is determined by a cut line detector. In the preferred embodiment, the cut line detector is an optical device. The washcloth is then cut by a cutting assembly and advanced to a predetermined location for maneuvering into the finishing area.
Based upon the position of the feed pull gripper at the time the detector senses the cut line of the washcloth, an axis Computer Numeric Controller ("CNC") determines the length of the washcloth. The width of the washcloth is also determined at the same time. The width is measured by an overhead camera as the washcloth advances along the predetermined path. The predetermined path has a reflective area thereon such that the camera can clearly locate the lateral edges of the washcloth.
After the washcloth is cut from the continuous strip and advanced to the predetermined location, the washcloth is engaged by a template attached to a gantry arm assembly. The template is lowered onto the exact center of the washcloth and maneuvers the washcloth along a calculated path into place adjacent to a sewing head. The template rotates the washcloth around the sewing head to finish the edges and corners of the washcloth. The template is guided by the controller based upon the determinations of length and width such that the washcloth is finished to its exact dimensions.
Thus, it is an object of the present invention to provide an improved method and apparatus for finishing a textile product.
It is another object of the invention to provide an improved method and apparatus for finishing a washcloth.
It is a further object of this invention to provide an automated method and apparatus for finishing washcloths which will accommodate washcloths of varying dimensions.
It is a still further object of the present invention to provide an improved method and apparatus to determine accurately the position of the cut line in a roll of terry cloth material and cut an individual washcloth from the roll along that cut line.
It is a still further object of the present invention to provide an improved method and apparatus to maneuver a washcloth into position and around a sewing head such that the corners of a washcloth are finished to uniform dimensions.
It is a yet another object of this invention to provide an improved method and apparatus for inserting labels into the edges or corners of a washcloth with a high degree of accuracy.
Other objectives, features and advantages of the present invention will become apparent upon reading a following specification, when taken in connection with the drawings and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the major elements of the preferred embodiment of the invention.
FIG. 2 is a plan view of the tabletop with the major elements of the preferred embodiment of the invention.
FIG. 3 is a side view of the tabletop, the intake assembly, the straightening gantry, the camera, the cutting assembly, the pull back assembly, the template, and the gantry frame assembly.
FIG. 4 is a front view of the straightening assembly.
FIG. 5 is a side view of the straightening assembly, the cutting assembly, and the camera.
FIG. 6 is a side view of the pull back assembly, the template, and the gantry frame assembly.
FIG. 7 is a side view of the sewing assembly.
FIG. 8 is a plan view of a washcloth and the continuous strip of terry cloth material.
FIG. 9 is a plan view of a washcloth.
DETAILED DESCRIPTION
Referring to the drawings, in which like numerals represent like parts throughout the several views, FIGS. 1 through 7 show the preferred embodiment of a washcloth finishing apparatus 10. FIGS. 1 through 3 show the major elements of the apparatus 10. This embodiment of the invention employs the use of an intake assembly 15, a straightening gantry assembly 20, a detector assembly 25, a cutting assembly 30, a pull back assembly 35, a camera 40, a template 45, a gantry frame assembly 50, a sew area assembly 55, and a removal assembly 57. All of these elements are mounted on a table top 60 in sequential fashion as shown. Further, the table top 60 may contain multiples of any of the above-referenced elements, such as two intake assemblies 15, straightening gantry assemblies 20, detector assemblies 25, cutting assemblies 30, pull back assemblies 35, cameras 40, templates 45, and removal assemblies 57, cooperatively operating with a single or multiple sew area assemblies 55.
The operation of the invention as a whole is governed by an axis CNC controller 61. The controller 61 may be a Delta Tau PMAC-PC model motion controller system with an eight axis servo control card, manufactured by Delta Tau Data Systems, or a similar type of system.
The intake assembly 15 is mounted at one end of the table top 60 along an intake path 65. The intake assembly 15 accommodates a continuous strip 70 of terry cloth or other material as it is fed into the assembly 10. The intake assembly 15 has a set of bars 16 through which the continuous strip 70 is guided onto the intake path 65 on the table top 60.
The continuous strip 70 is generally layered within a buggy or mounted in roll form. As is shown in FIG. 8, the continuous strip 70 has transverse borders or cut lines 71 present in essentially uniform intervals. The cut line 71 is an area in the continuous strip 70 with no terry loops or other plush material. The cut line 71 also may include a small gap or gaps in the fabric. The cut line 71 indicates where the continuous strip 70 is to be cut to form an essentially rectangular or square panel. In this embodiment, the panel is in the form of a washcloth 72.
As is shown in FIGS. 4 and 5, the straightening gantry assembly 20 is mounted to the table top 60 along the intake path 65. The straightening gantry assembly comprises a holding bar 74 with a holding bar air cylinder 79, several mechanical pusher rods 75 with pusher rod air cylinders 78, and a straightening plate 76. The mechanical pusher rods 75 and the straightening plate 76 are in turn mounted to an assembly air cylinder 77.
The mechanical pusher rods 75 are generally in the shape of a inverse "T" and are positioned over a recess 31 adjacent to the cutting assembly 30. The straightening plate 76 is rectangularly shaped and extends the width of the intake path 65. The pusher rods 75 and the straightening plate 76 are powered by the assembly air cylinder 77 for up and down motion therewith. The pusher rods 75 are further powered by the pusher rod air cylinders 78 for extended motion into the recess 31. The holding bar 74 is positioned behind the straightening plate 76 and is powered for up and down motion by the holding bar air cylinder 79.
As is shown in FIG. 3, the camera 40 is mounted upon the straightening gantry assembly 20 such that the camera 40 has a view of the intake path 65 from the straightening gantry assembly 20 to the pull back assembly 35. The camera 40 can be any kind of conventional camera, photo-eye, or other optical monitoring device. The intake path 65 has a reflective surface 80, such as a piece of reflective tape, thereon to ensure that the camera 40 can differentiate between the intake path 65 on the table top 60 and the continuous strip 70.
The pull back assembly 35 is mounted on the table top 60 along the intake path 65. The pull back assembly 35 comprises a feed pull gripper 85 attached to a servo motor 87. More than one feed pull gripper 85 may be employed within the pull back assembly 35. The feed pull gripper 85 grabs the continuous strip 70 as it is emerges from the straightening gantry assembly 20 and pulls the continuous strip 70 along the intake path 65 through the cutting assembly 30 and onto a predetermined location on the table top 60.
The detector assembly 25 determines the location of the cut line 71 and other boundaries of the washcloth 72. The detector assembly 25 includes two optical sensors 95 positioned along the intake path 65 of the table top 60. In this embodiment, the optical sensors 95 are analog photo-eyes that can detect changes in the thickness or density of the continuous strip 70. The analog output of the optical sensors 95 to the controller 61 changes proportionally to the thickness or density of the cloth. The optical sensors 95 can be used with any thickness or color of cloth. Alternatively, any type of detector controls may be employed, including optical, electrical, or pneumatic. One or more detector assemblies 25 may be used.
In connection with the detector assembly 25, the straightening gantry assembly 20 also may include a bias correction device 250 to ensure that the position of the cut line 71 is straight as it approaches the cutting assembly 30. The bias correction device 250 comprises a straightening bar 255 mounted on the table top 60 adjacent to the intake assembly 15, and an edge guide apparatus 260 positioned between the straightening bar 255 and the cutting assembly 30. The bias correction device 250 also employs the use of the optical sensors 95. Because at least two optical sensors 95 are used, the sensors 95 also can determine whether the cut line 71 is perpendicular to the intake path 65. Any angle or bias in the cut line 71 can be determined by measuring the timing of the change in output of the two sensors 95. This difference causes the controller 61 to tilt the straightening bar 255 in one direction or another to compensate for the bias in the continuous strip 70.
The edge guide apparatus 260 comprises two rotatable wheels 265 that descend along the edge of the continuous strip 70 to ensure that the absolute edges on both sides of the continuous strip 70 remain along the same line. The edge guide apparatus also comprises several additional optical sensors 95 positioned along the edge of the continuous strip 70 because the continuous strip 70 tends to move to the right or the left when the straightening bar 255 corrects the bias therein. The optical sensors 95 detect any drift in the continuous strip 70 and activate the rotatable wheels 265 accordingly.
As is shown in FIG. 5, the cutting assembly 30 is positioned under the table top 60 in the middle of the recess 31 in the intake path 65. The intake path 65 has a raised plate 32 positioned thereon just prior to the recess 31. The cutting assembly 60 comprises a blade 105 powered by an electrical motor 106. The blade 105 is also attached to and activated by a cutting blade air cylinder 115 for reciprocal movement along the recess 31. The blade 105 is activated for movement along the recess 31 by a signal from the controller 61 to coincide with the depression of the pusher rods 75 to accurately cut the washcloth 72.
The gantry arm assembly 50 is positioned on the table top 60 and comprises a gantry arm 125, one or more fixed rails 130, a template frame 135, and the template 45. The template 45 is operably mounted within the template frame 135 for rotation about the Z, or vertical, axis. The template 45 also can be raised or lowered towards the table top 60 so as to engage the washcloth 72. The template frame 135 is supported by the gantry arm 125 for movement thereon along the Y axis. The gantry arm 125 is mounted on the one or more fixed rails 130 for movement thereon along the X axis. The result is that the template 45 can maneuver along the X, Y, and Z axes and also :rotate about the Z axis. The template 45 is powered by one or more electrical drive motors 140. The drive motors 140 are governed by directional instructions received from the controller 61 such that the washcloth 72 is maneuvered along a calculated path 190, described below.
The sew area assembly 55 is also mounted on the table top 60 as is shown in FIG. 7. The sew area assembly 55 includes a sewing head 145 powered by a sewing motor 150. The sewing motor 150 is generally a two horsepower electrical motor. A Mauser brand or similar sewing head may be employed. The sewing head 145 is fed with thread from spindles 147. The sewing head 145 may be equipped with an integral blade 155 and a spring-loaded tracking arm 156. The sew area assembly 55 also may be equipped with more than one sewing head 145 depending upon the number of elements mounted on the table top 60. Further, more than one type of sewing head 145 may be employed to give the apparatus 10 versatility in accommodating various types of washcloths 72.
The removal assembly 57 is mounted on the table top 60 adjacent to the sew area assembly 55. The removal assembly 57 comprises a "T" shaped engagement arm 160 capable of reciprocal movement. The engagement arm 160 engages the washcloth 72 by pulling it along the table top 60 after the template 45 has maneuvered the washcloth 72 around the sewing head 145. The engagement arm 160 pulls the washcloth along the table top 60 to a predetermined placement location.
In the preferred embodiment of FIGS. 1 through 7, the washcloth finishing apparatus 10 processes the continuous strip 70 in sequential fashion. The continuous strip 70 is positioned in the intake assembly 15 and advanced along the intake path 65. One end of the continuous strip 70 is fed into the straightening gantry assembly 20 and engaged by the feed pull gripper 85. The straightening gantry assembly 20 ensures that the incoming cut line 71 on the continuous strip 70 is perpendicular to the intake path 65 and parallel to the cutting assembly 30 by the use of the straightening plate 76. The straightening plate 76 descends upon the fabric and intersects the cut lines 71. The cut lines 71 are forced against the plate 76 as the feed pull gripper 85 pulls the continuous strip 70 forward to remove any angle or bow that may be present. The pusher rods 75 then descend and force the continuous strip 70 into the recess 31 adjacent to the cutting assembly 30. The holding bar 74 secures the continuous strip 70 behind the straightening plate 76 to ensure that the continuous strip 70 remains in place as the washcloth 72 is cut.
As the continuous strip 70 advances along the intake path 65, the location of each cut line 71 is determined by the optical sensors 95 of the washcloth detector assembly 25. The cut line 71 is of lesser density then that of the surrounding plush fabric of the continuous strip 70. The optical sensors 95 determine the position of the cut line 71 by sensing the change in density of the continuous strip 70. When the cut line 71 passes over the optical sensors 95, the output of the sensors 95 changes in magnitude and duration. This change is monitored and the position of the cut line 71 is determined by the controller 61.
This determination of the position of cut line 71 by the optical sensors 95 also may be used by the bias correction device 250 to further ensure that the cut line 71 is straight before the continuous strip 70 reaches the cutting assembly 30. Any difference in the timing of the detection of the cut line 71 by the respective optical sensors 95 causes the straightening bar 255 to correct the bias in the continuous strip 70 by tilting in the opposite direction from the bias. The edge guide apparatus 260 keeps the edges of the continuous strip 70 in line while the straightening bar 255 is tilted.
As the continuous strip 70 is advanced by the feed pull gripper 85 through the cutting assembly 30, the blade 105 is triggered by the determination of the position of the cut line 71. The controller 61 is aware of the exact position of the cut line 71 at all times based upon the detection of the cut line 71 by the detector assembly 25. Based upon this information, the feed pull gripper 85 advances the continuous strip 70 such that the blade 105 cuts an individual washcloth 72 exactly at the location of the cut line 71. The washcloth 72 is then pulled by the feed pull gripper 85 to a predetermined location at the intersection of the end of the intake path 65 and the beginning of the calculated path 190 and released.
The length 170 of each washcloth 72 is calculated based upon the determination of the location of the cut line 71. The controller 61 calculates the exact length 170 of each washcloth 72 based upon the position of the feed pull gripper 85 along the intake path 65 at the time the detector assembly 25 senses the presence of a cut line 71, in combination with the known amount of advance of the feed pull gripper 85.
The width 175 of each individual washcloth 72 is also determined as the continuous strip 70 advances along the intake path 65. The width 175 is measured by the overhead camera 40 mounted to the straightening gantry assembly 20. The intake path 65 has a reflective surface 80 thereon such that the camera 40 can locate the edges of each washcloth 72 and measure the width 175. Approximately three measurements are taken for the width 175 of each washcloth 72 as the continuous strip 70 is advanced. These sums are averaged and the width 175 of each washcloth 72 is determined by the controller 61. The camera 40 can be any type of device by which the perimeter of each washcloth 72 can be determined, such as video monitoring, imaging, or the use of a photo-electrical beam.
Based upon the determination of the length 170 and the width 175 for the washcloth 72, and the distance traveled by the feed pull gripper 85, the exact center 185 of the washcloth 72 is also known. The washcloth 72 is then engaged at its center 185 by the template 45 associated with the gantry frame assembly 50. The template 45 maneuvers the washcloth 72 along the calculated path 190 into position in the sewing area assembly. As described above, the gantry arm 125, in combination with the template 45, permits maneuvering of the washcloth 72 along the calculated path 190 in both the X and the Y axes. The template 45 also can rotate about the Z axis within the template frame 135.
Once the washcloth is maneuvered into position in the sewing area 55, the template 45 rotates the washcloth 72 around the sewing head 145 to finish the edges and the corners of the washcloth 72. The sewing head 145 stitches each edge of the washcloth 72 based upon the determination of the length 170 and the width 175. The corners of each washcloth 72 are also automatically rounded. Another camera 40 or further optical sensors 95 also can be located over the sew area assembly 55 and provide information regarding out of square edges on the washcloth 72. In this embodiment, optical sensors 95 are mounted adjacent to the sewing head 145. Out of square edges are detected by the optical sensors 95 and are compensated for as the washcloth 72 is maneuvered around the sewing head 145.
By positioning two optical sensors 95 adjacent to the sewing head 145, the sensors 95 can also detect the exact location of a corner of the washcloth 72 so as to accurately cause the template 45 to begin to rotate. As the turn is completed, the optical sensors 95 accurately detect the position and depth of the next side of the washcloth 72. In this manner, any angle in the washcloth 72 is accounted for to ensure that the sewing head 145 does not does not miss an edge or a corner and the washcloth 72 is evenly finished.
As the sewing head 145 advances around the washcloth 72, the sewing head 145 is kept in position with the help of the tracking arm 156. The tracking arm 156 rides along the template 45 and forces the template 45 to hold the washcloth 72 in position. When each edge of the washcloth 72 is finished, the sewing head 145 "sews off" or slightly overlaps the stitches to prevent the stitches from unraveling. As the washcloth 72 is maneuvered around the sewing head 145, the integral blade 155 also cuts away any excess material.
As is shown in FIG. 9, the starting point of the arc P1, the center of rotation R, and the ending point of the arc P2 are calculated for each corner of the washcloth 72 using the known speed of the template 45 and other experimentally-determined coordinates. The operator of the apparatus 10 also has the ability to modify the position of the starting point of the arc P1. This gives the operator the ability to control how "round" a given corner is finished. The operator also can change the speed in which the sewing head 145 advances along the sides of the washcloth 72 to accommodate washcloths 72 of varying thickness and density.
The engagement arm 160 of the removal assembly 57 then engages the washcloth 72 and pulls it to the side of the table top 60 for removal from the apparatus 10. The removal assembly 57 also may drop the washcloth 72 into a holding area (not shown) for stacking.
By determining the dimensions of the washcloth 72 to a high degree of accuracy, the apparatus 10 is also able to insert labels 200 onto the edges or corners of the washcloth 72. A label insertion apparatus 205 with a rotating arm 210 may be positioned adjacent to the intake path 65. As the washcloth 72 is released by the feed pull gripper 85 at the predetermined location, the rotating arm 210 of the label insertion apparatus 205 may place a label 200 on one side of the washcloth 72. The template 45 secures the label 200 on the washcloth 72 and the label 200 is sewn into position as the washcloth 72 travels around the sewing head 145. Alternatively, the label insertion apparatus may include a plate 211 in which the labels 200 are positioned. The plate 211 is extended by the label insertion apparatus 205 into position over the washcloth 72 where the plate 211 releases the label 200. More than one label 200 can be inserted on a washcloth 72.
As an alternative embodiment, the sewing head 145 itself is capable of rotation about the Z axis. The movement of the template 45 can then be limited to two directions of movement. The template 45 advances the washcloth 72 adjacent to the sewing head 145 and the controller 61 then guides the sewing head 145 and the template 45 based upon the predetermined length 170 and width 175 dimensions.
Further, the camera 40 or other detection device also can be located over the sew area assembly 55 and receive information on both the length 170 and the width 175 of the washcloth 72. This information on the dimensions of the washcloth 72 may then be used by the controller 61, as described above, to guide the washcloth 72 through the sewing head 145. The camera 40 can determine the dimensions of the entire washcloth 72 to guide the template 45 and the washcloth 72 around the sewing head 145 regardless of the means for cutting each washcloth 72 from the continuous strip 70. Likewise, the sewing head 145 itself can maneuver in and out to compensate for variations in the edges. By using this information, the sewing head 145 can track and follow the actual edge of the washcloth 72.
The result of these embodiments is an apparatus 10 capable of producing a high quality washcloth 72 finished to its exact dimensions. Such a finish is ensured by the determination of the dimensions of each washcloth 72 by the controller 61 to guide the template 45. The controller 61 can react to varying dimensions and also permit size changes without the need for mechanical alterations to the apparatus 10. The apparatus 10 can finish the edges of washcloths 72 ranging in length from 11 to 15 inches. An average of 6 to 6.5 washcloths per minute can be produced based upon a 12 inch washcloth 72.
While the invention has been disclosed as finishing the edges of terry cloth washcloths, other types of fabric and materials can be used. Likewise, the invention can finish the edges of products other than washcloths, such as napkins, towels, place mats, floor mats, rugs, and the like.
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A method and apparatus for manufacturing a textile product from a continuous strip of material having borders defining discrete panels. The apparatus pulls the strip along a pre-determined path. As the strip is advanced, the border of a panel is detected. Based upon the distance the panel is advanced after the detection of the border, the length of each panel is determined while the width of each panel is measured. Each panel is then cut from the strip and maneuvered along a calculated path for finishing based upon the determination of length and width.
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This application corresponds to Korean patent application No. 67794/1995 filed Dec. 30, 1995 in the name of Samsung Electronics Co., Ltd., from which priority is claimed.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to semiconductor memory devices, and more particularly to a circuit for generating a high voltage power supply in a semiconductor memory device.
2. Description of the Prior Art
As semiconductor memory devices become more highly integrated, lower operating supply voltages must be used to reduce stress on circuits and elements resulting from high electric fields from the power supply. However, even memory devices that operate at reduced power supply voltages often require a high voltage power supply for certain circuits and operations such as driving a word line during an enable operation and driving an isolation gate control signal which is used to selectively switch isolation gates in memory devices having a charge sharing sense amplifier configuration.
Various pumping circuits for generating high voltages have been developed. The circuits are generally classified into two types: standby pumping circuits which supply small amounts of current at a high voltage level, and active pumping circuits which typically supply larger amounts of current at high voltages than the standby circuits, since the amount of charge used by a semiconductor memory device in active mode is typically larger than that used in standby mode.
FIG. 1 is a block diagram of a conventional high-voltage generating circuit (also called a pumping voltage generating circuit) for use in standby mode in a semiconductor memory device. As shown in FIG. 1, a conventional standby high voltage generating circuit includes an oscillator 10, and pumping means 12 having an input terminal connected to an output terminal of the oscillator 10. The pumping means 12 also has a voltage terminal for inputting a first (or internal) supply voltage which is used as the operating power supply for the chip. The pumping means 12 has an output terminal for outputting a second supply voltage or desired high voltage which is higher in level than the external supply voltage. The conventional standby high voltage generating circuit further includes a detector 14 connected in a feedback manner between the output terminal of the pumping means 12 and an input terminal of the oscillator 10.
In operation, the pumping means 12 (typically a charge pump) boosts the voltage of the first power supply signal to a higher voltage second power supply voltage signal in response to a train of periodic pulses generated by oscillator 10. The detector 14 detects the voltage level of the second power supply signal and, in accordance with the detected signal, controls the oscillator to prevent the second power supply voltage level from exceeding a predetermined level. Thus, the circuit of FIG. 1 pumps the first power supply voltage to a second power supply voltage in a standby mode.
FIG. 2 is a block diagram of a conventional high voltage generating circuit for a use in active mode in a semiconductor memory device. As shown in this drawing, the conventional active high voltage generating circuit includes an active kicker enable circuit 16, and pumping means 18 having an input terminal connected to an output terminal of the active kicker enable circuit 16. The pumping means 18 also has a voltage terminal for inputting a first (or internal) supply voltage which is used as the operating power supply for the chip. The pumping means 18 has an output terminal for outputting a second supply voltage or desired high voltage which is higher in level than the external supply voltage.
In operation, the active kicker enable circuit 16 generates a master clock signal at a frequency in accordance with the demands of the circuits in the semiconductor memory device which require a high voltage supply. The pumping means (charge pump) 18 boosts the voltage level of the first power supply signal to the voltage level of the second power supply signal in response to the master clock signal from the active kicker enable circuit 16. As a result, the circuit of FIG. 2 supplies a large amount of charge at a high voltage level to the semiconductor memory device in the active mode. The amount of charge supplied is determined in accordance with the demands of the semiconductor memory device.
The construction and operation of the prior art standby and active pumping generating circuits of FIGS. 1 and 2 are well-known, and thus will not be described further.
However, the prior art high voltage generating circuits have several disadvantages. First, since the amount of charge required in active mode is significantly greater than the amount required in standby mode, two separate circuits must be used to generate the high voltage power supply during the two separate modes of operation.
Second, the large capacity active high voltage generating circuit increases power supply noise because it is operated in response to one master clock which results in large amounts of charge being temporarily charged and discharged.
Third, the pumping means in the active high voltage generating circuit includes a large capacity capacitor for supplying large amounts of current. The charging and discharging of this capacitor reduces the pumping efficiency and reduces the level of integration of the semiconductor memory device.
Fourth, because the large capacitor is activated for pumping operation, the pumping time increases thereby resulting in a degradation of high speed operation.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a high voltage generating circuit for a semiconductor memory device which is capable of operating in both standby and active modes.
Another object of the present invention is to reduce the size of the capacitors required for a high voltage generating circuit for a semiconductor memory device so as to increase the pumping efficiency.
A further object of the present invention is to reduce power supply noise in a semiconductor memory device.
Another object of the present invention is to increase the operating speed of a semiconductor memory device.
Yet another object of the present invention is to increase the integration level of a semiconductor memory device.
To achieve these and other objects, a high voltage generating circuit in accordance with the present invention employs a plurality of charge pumping circuits which are coupled to an output line and repetatively activated in sequence. Each pump operates for a predetermined on time after it is activated. In standby mode, the pumps are activated at a low frequency so that the amount of time between the activation of successive pumps is longer than the predetermined on time, and thus, each pump is deactivated before the next pump is activated. This results in only a small amount of charge being transferred to the output line during standby mode. In active mode, the pumps are activated at a higher frequency such that the on times of the individual pumps overlap and several pumps operate simultaneously. Thus, a larger amount of charge is transferred during active mode. Since the individual pumps are activated at different times, power supply noise is reduced.
One aspect of the present invention is a method for generating a high voltage power supply in a semiconductor memory device comprising the steps of operating one pumping circuit during a standby mode to transfer charge to an output line; and operating a plurality of pumping circuits during an active mode to transfer charge to the output line. The plurality of pumping circuits are activated in a sequential manner.
Another aspect of the present invention is a method for generating a high voltage power supply in a semiconductor memory device comprising: sequentially activating a plurality of pumping circuits; sequentially deactivating the plurality of pumping circuits; and increasing the frequency at which the pumping circuits are activated during an active mode. The frequency at which the pumping circuits are activated is decreased during a standby mode.
Another aspect of the present invention is a circuit for generating a high voltage power supply in a semiconductor memory device, the circuit comprising two or more pumping circuits coupled to an output line, wherein one of the pumping circuits transfers charge to the output line during a standby mode, and at least two of the pumping circuits transfer charge to the output line during an active mode. Each of the pumping circuits transfers charge to the output line responsive to one of a plurality of enable signals. The circuit includes an enable signal generating circuit coupled to the pumping circuits for generating the plurality of enable signals. The enable signal generating circuit includes a shift register coupled to the pumping circuits to activate the enable signals in sequence.
An advantage of the present invention is that a single high voltage generating circuit can be used to supply a high voltage signal in both standby and active modes in a semiconductor memory device.
Another advantage of the present invention is that it does not require a large capacity capacitor. This prevents the abrupt charging and discharging, thereby significantly reducing power supply noise.
A further advantage of the present invention is that it employs small capacitors which increased the pumping efficiency as well as the level of integration of the semiconductor memory device. The use of small capacitors also reduces the pumping time, thereby improving high speed operation.
The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment of the invention which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a prior art high voltage generating circuit for use in standby mode in a semiconductor memory device;
FIG. 2 is a block diagram of a prior art high voltage generating circuit for use in active mode in a semiconductor memory device;
FIG. 3 is a block diagram of a first embodiment of a high voltage generating circuit in accordance with the present invention;
FIG. 4 is a timing diagram illustrating the operation of the circuit of FIG. 3;
FIG. 5 is a block diagram of a second embodiment of a high voltage generating circuit in accordance with the present invention;
FIG. 6 is a timing diagram illustrating the operation of the circuit of FIG. 5;
FIG. 7 is a block diagram of a third embodiment of a high voltage generating circuit in accordance with the present invention; and
FIG. 8 is a timing diagram illustrating the operation of the circuit of FIG. 7.
DETAILED DESCRIPTION
FIG. 3 is a block diagram of a first embodiment of a high voltage generating circuit in accordance with the present invention. The circuit of FIG. 3 includes an active kicker enable circuit 20 for generating a pulse signal P0 at its output terminal which is connected in common to an input terminal of a delay element 22 and a first input terminal of a first gating means or NOR gate 32. The delay element 22 outputs a pulse signal P1 at its output terminal which is connected in common to an input terminal of a delay element 24 and a second input terminal of the NOR gate 32. The delay element 24 outputs a pulse signal P2 at its output terminal which is connected in common to an input terminal of a delay element 26 and a third input terminal of the NOR gate 32. The delay element 26 outputs a pulse signal P3 at its output terminal which is connected in common to an input terminal of a delay element 28 and a fourth input terminal of the NOR gate 32. The delay element 28 outputs a pulse signal P4 at its output terminal which is connected in common to an input terminal of a delay element 30 and a fifth input terminal of the NOR gate 32. The delay element 30 outputs a pulse signal P5 at its output terminal which is connected to a sixth input terminal of the NOR gate 32. The first gating means or NOR gate 32 generates a control signal ODB at its output terminal which is connected to a first input terminal of a second gating means or AND gate 36.
The high voltage generating circuit further includes an oscillator 34 for generating an output signal φOSC in the form of a pulse train at its output terminal which is connected to a second input terminal of the AND gate 36. The AND gate 36 outputs a clock signal φCLK at its output terminal which is connected in common to an output enable terminal OE and a clock input terminal CLK of a shift register 38. The shift register 38 generates output signals s1-s4 at its output terminals which are connected to the second input terminals of OR gates 40-46, respectively. The first input terminals of OR gates 40-46 receive the pulse signals P1-P4 from the delay elements 22-28, respectively. The OR gates 40-46 generate enable signals e1-e4, respectively, at their output terminals which are connected to input terminals of pumping means 48-54, respectively.
The NOR gate 32, AND gate 36, shift register 38 and OR gates 40-46 operate so as to control the pumping means 48-54. The pumping means 48-54 have voltage terminals for inputting a first supply voltage or internal supply voltage which is used as an operating power supply in a chip. The pumping means 48-54 also have output terminals which are commonly connected to output a second supply voltage, or pumped voltage, which is higher in level than an external supply voltage.
The high voltage generating circuit further includes a detector 56 connected in a feedback manner between the output terminals of the pumping means 48-54 and an input terminal of the oscillator 34. More specifically, the detector 56 has an input terminal connected in common to the output terminals of the pumping means 48-54, and an output terminal connected to the input terminal of the oscillator 34.
The operation of the circuit of FIG. 3 will now be described with reference to FIG. 4 which is a timing diagram illustrating the operation of the circuit of FIG. 3 in both standby mode and active mode.
In standby mode, the output signals from the active kicker enable circuit 20 and delay elements 22-30 are all at a low logic level. As a result, the control signal ODB, which is the output signal from the NOR gate 32, remains at a high logic state. In this state, the oscillator 34 generates an output signal φOSC in the form of pulse train, and the AND gate 36 generates a clock signal φCLK with the same pulse train waveform as that of the output signal φOSC from the oscillator 34. Then, the shift register 38 generates output signals corresponding to the output signal φCLK from the AND gate 36. That is, the shift register 38 enables its output signals s2 and s3, as shown in FIG. 4, which are then applied respectively to the OR gates 42 and 44 an logically combined with the pulse signals P2 and P3 from the delay elements 24 and 26. In accordance with the logically combined results, the OR gates 42 and 44 output the enable signals e2 and e3 respectively to the pumping means 50 and 52. As a result, the pumping means 50 and 52 pump the first supply voltage to the second supply voltage.
Thus, in standby mode, each of the pumping means are activated in sequence. However, the frequency of activation is low enough that each pumping means is deactivated before the next pumping means is activated.
In active mode, the active kicker enable circuit 20 generates the pulse signal P0, thereby causing the delay elements 22-30 to generate the pulse signals P1-P5. In response to the pulse signals P0-P5 from the active kicker enable circuit 20 and delay elements 22-30, the NOR gate 32 generates the control signal ODB which remains at its low logic state for a predetermined time period. The active kicker enable circuit 20 is designed to generate a master clock with a pulse duration which is longer than that of the delay means with the longest delay time. As a result, the control signal ODB from the NOR gate 32 remains at its low logic state from the low to high transition of the pulse signal P0 from the active kicker enable circuit 20 until the high to low transition of the pulse signal P5 from the delay element 30, to stop the operation of the shift register 38. This causes the output signals s1-s4 from the shift register 38 remain at their low logic state. On the other hand, the OR gates 40-46 logically combine the pulse signals P1-P4 from the delay elements 22-28 with the output signals s1-s4 from the shift register 38, respectively. In accordance with the logically combined results, the OR gates 40-46 generate their output signals e1-e4 corresponding respectively to the pulse signals P1-P4 from the delay elements 22-28. As a result, all four of the pumping means 48-54 perform the pumping operation in an overlapping manner to pump the first supply voltage to the second supply voltage, so as to transfer a large amount of charge to an output line.
Thus, in active mode, each of the pumping means are activated in sequence. However, the frequency of activation is increased from that used in standby mode to the point that each successive pumping means is not deactivated until after the next pumping means has been activated. In the example of FIG. 4, there is a time during which all four pumping means are actally operating simultaneously, thereby transfering a large amount of charge to the output line.
An advantage of this technique is that it allows a single circuit to transfer a large amount of charge during active mode, and a smaller amount of charge during standby mode. Another advantage is that, as can be seen from FIG. 4, each of the pumping means turns on at a different time rather than all at once. This eliminates the noise that would be generated by the current surge that would occur if all of the pumping means were activated at once.
FIG. 5 is a block diagram of a second embodiment of a high voltage generating circuit in accordance with the present invention. As shown in FIG. 5, the high voltage generating circuit includes an active kicker enable circuit 60 for generating a pulse signal P0 at an output terminal which is connected in common to an input terminal of a delay element 62 and a set terminal of an oscillator control circuit 72. The delay element 62 outputs a pulse signal P1 at its output terminal which is connected to an input terminal of a delay element 64. The delay element 64 outputs a pulse signal P2 at its output terminal which is connected to an input terminal of a delay element 66. The delay element 66 outputs a pulse signal P3 at its output terminal which is connected to an input terminal of a delay element 68. The delay element 68 outputs a pulse signal P4 at its output terminal which is connected to an input terminal of a delay element 70. The delay element 70 outputs a pulse signal P5 at its output terminal which is connected to a reset terminal of the oscillator control circuit 72. The oscillator control circuit 72 generates a control signal ODB at its output terminal which is connected to a first input terminal of first gating means or AND gate 76.
The high voltage generating circuit further includes an oscillator 74 for generating an output signal φOSC in the form of a pulse train at its output terminal which is connected to a second input terminal of the AND gate 76. A second gating means or OR gate 78 having four input terminals for inputting the pulse signals P1-P4 from the delay elements 62-68, respectively. A third gating means or OR gate 80 has first and second input terminals connected respectively to output terminals of the OR gate 78 and AND gate 76. The OR gate 80 outputs a clock signal φCLK at its output terminal which is connected to a clock input terminal CLK of a shift register 82. The shift register 82 generates output signals s1-s4 at its output terminals which are connected respectively to input terminals of pulse generators 84-90. The pulse generators 84-90 generate enable signals e1-e4 respectively at their output terminals which are connected respectively to input terminals of pumping means 92-98.
The oscillator control circuit 72, AND gate 76, OR gates 78 and 80, shift register 82 and pulse generators 84-90 are operated to control the pumping means 92-98. The pumping means 92-98 have voltage terminals for commonly inputting a first supply voltage or internal supply voltage which is used as the operating power supply in a chip. The pumping means 92-98 also have output terminals which are commonly connected to output a second supply voltage, or pumped voltage, which is higher in level than an external supply voltage.
The high voltage generating circuit further includes a detector 100 connected in a feedback manner between the output terminals of the pumping means 92-98 and an input terminal of the oscillator 74. More specifically, the detector 100 has an input terminal connected to the output terminals of the pumping means 92-98, and an output terminal connected to the input terminal of the oscillator 74.
The operation of the circuit of FIG. 5 will now be described with reference to FIG. 6 which is a timing diagram illustrating the operation of the circuit of FIG. 5 in both standby mode and active mode.
In standby mode, the output signals from the active kicker enable circuit 60 and delay elements 62-70 are all at a low logic level. As a result, the control signal ODB or output signal from the oscillator control circuit 72 remains at its high logic state. In this state, the oscillator 74 generates the output signal φOSC in the form of a pulse train, and the AND gate 76 generates an output signal with the same pulse train waveform as that of the output signal φOSC from the oscillator 74. Also, the output signal from the OR gate 78 remains at its low logic state because the output signals from the delay elements 62-68 are all low. As a result, the OR gate 80 generates the clock signal φCLK with the same pulse train waveform as that of the output signal from the AND gate 76. Then, the shift register 82 generates its output signals corresponding to the output signal φCLK from the OR gate 80. That is, in response to the output signal φCLK from the OR gate 80, the shift register 82 enables its output signals s2 and s3, as shown in FIG. 6, which are then applied respectively to the pulse generators 86 and 88. In response to the output signals s2 and s3 from the shift register 82, the pulse generators 86 and 88 output the enable signals e2 and e3 respectively to the pumping means 94 and 96. As a result, the pumping means 94 and 96 pump the first supply voltage to the second supply voltage.
Thus, in standby mode, each of the pumping means are activated in sequence. However, the frequency of activation is low enough that each pumping means is deactivated before the next pumping means is activated.
In active mode, the active kicker enable circuit 60 generates the pulse signal P0, 10 thereby causing the delay elements 62-70 to generate the pulse signals P1-P5. The pulse signals P0 and P5 from the active kicker enable circuit 60 and delay element 70 are applied to the set and reset terminals of the oscillator control circuit 72, respectively. As a result, the oscillator control circuit 72 generates the control signal ODB which remains at its low logic state for a predetermined time period. The active kicker enable circuit 60 is designed to generate a master clock with a pulse duration which is shorter than that of the delay means with the shortest delay time. As a result, the control signal ODB from the oscillator control circuit 72 remains at its low logic state from the low to high transition of the pulse signal P0 from the active kicker enable circuit 60 until the high to low transition of the pulse signal P5 from the delay element 70, to stop the operation of the shift register 82. Also, the OR gate 78 logically combines the pulse signals P1-P4 from the delay elements 62-68 and transfers the logically combined result to the clock input terminal of the shift register 82. Then, the shift register 82 sequentially outputs the output signals s1-s4 which are all high in logic. The pulse generators 84-90 generate their enable signals e1-e4 corresponding respectively to the output signals s1-s4 from the shift register 82. As a result, the pumping means 92-98 perform the pumping operation four times to pump the first supply voltage to the second supply voltage, so as to transfer a large amount of charge to an output line.
Thus, in active mode, each of the pumping means are activated in sequence. However, the frequency of activation is increased from that used in standby mode to the point that each successive pumping means is not deactivated until after the next pumping means has been activated. In the example of FIG. 6, there is a time during which all four pumping means are actally operating simultaneously, thereby transfering a large amount of charge to the output line.
FIG. 7 is block diagram of a third embodiment of a high voltage generator circuit in accordance with the present invention. As shown in FIG. 7, the high voltage generating circuit comprises an active kicker enable circuit 110 having an output terminal connected to a first input terminal of a variable oscillator 112. The variable oscillator 112 generates a clock signal φCLK at its output terminal which is connected to a clock input terminal CLK of a shift register 114. The shift register 114 generates output signals s1-s4 at its output terminals which are connected respectively to input terminals of pulse generators 116-122. The pulse generators 116-122 generate enable signals e1-e4 respectively at their output terminals which are connected respectively to input terminals of pumping means 124-130.
The shift register 114 and pulse generators 116-122 are operated to control the pumping means 124-130 in response to the clock signal φCLK from the variable oscillator 112. The pumping means 124-130 have voltage terminals for commonly inputting a first supply voltage or internal supply voltage which is used as the operating power supply in a chip. Further, the pumping means 124-130 have output terminals for commonly outputting a second supply voltage or pumped voltage which is higher in level than an external supply voltage.
The high voltage generating circuit further includes a detector 132 connected in a feedback manner between the output terminals of the pumping means 124-130 and a second input terminal of the variable oscillator 112. More specifically, the detector 132 has an input terminal connected in common to the output terminals of the pumping means 124-130 and an output terminal connected to the second input terminal of the variable oscillator 112.
The operation of the circuit of FIG. 7 will now be described with reference to FIG. 8 which is a timing diagram illustrating the operation of the circuit of FIG. 7 in both standby mode and active mode. In the third embodiment of FIG. 7, the variable oscillator 112 is designed to generate the clock signal φCLK with a variable pulse duration. That is, the clock signal φCLK from the variable oscillator 112 has a longer pulse duration in standby mode and a shorter pulse duration in active mode. As a result, the pumping operation is performed once in the standby mode to supply a pumped voltage to an output line. In the active mode, the pumping operation is successively performed four times to supply a large amount of charge to the output line. The remaining operation of the third embodiment in FIG. 7 is substantially the same as those of the first and second embodiments in FIGS. 3 and 5 and a description thereof will thus be omitted.
Having described and illustrated the principles of the invention in a preferred embodiment thereof, it should be apparent that the invention can be modified in arrangement and detail without departing from such principles. We claim all modifications and variations coming within the spirit and scope of the following claims.
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A high voltage generating circuit for a semiconductor memory device includes a plurality of charge pumps which are connected to a common output line and repetatively activated in sequence. Each pump operates for a predetermined on time after it is activated. In standby mode, the pumps are activated at a low frequency so that the amount of time between the activation of successive pumps is longer than the predetermined on time, and thus, each pump is deactivated before the next pump is activated. This results in only a small amount of charge being transferred to the output line during standby mode. In active mode, the pumps are activated at a higher frequency such that the on times of the individual pumps overlap and several pumps operate simultaneously. Thus, a larger amount of charge is transferred during active mode. Since the individual pumps are activated at different times, power supply noise is reduced.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, and hereby incorporates by reference, U.S. Provisional Application No. 61/260,393, filed Nov. 11, 2009 and entitled “Interlock Mechanism for a Multiple Battery Pack.”
TECHNICAL FIELD
[0002] The present invention relates to battery systems.
BACKGROUND
[0003] For electrical equipment that uses batteries and requires high power, such as electric or hybrid vehicles, the battery system will often contain multiple battery packs, only one of which will be powering the system at any time. The battery system therefore needs be able to switch from one pack to another in a manner that protects the battery packs and contactors, especially while the vehicle is in operation. Conventional systems with multiple packs generally switch to a different pack by shutting the load off completely regardless of the state of the operation and waiting for a long period to switch over. This can result in potentially dangerous problems including long switchover times that disable the vehicle operation for a long duration or switch over while the vehicle is midst of acceleration.
[0004] An example of a battery system for an electric vehicle with N battery packs is shown in FIG. 1 , where N is 2 or greater. In this system, only one of the battery packs is connected to the vehicle load at a time. When the charge in battery pack 1 is exhausted, the system may switch to the next battery pack with available charge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present invention is illustrated by way of example, and not limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0006] FIG. 1 illustrates an exemplary diagram of an existing multiple battery pack system;
[0007] FIG. 2A illustrates an exemplary diagram of a multiple battery pack system with reduced battery pack switchover delays;
[0008] FIG. 2B shows an exemplary system diagram for a battery management system;
[0009] FIG. 3 illustrates an exemplary sequence of operations to switch between battery packs in a multiple battery pack system;
[0010] FIG. 4 illustrates an exemplary graph of the relationship between voltage and time during a battery pack switch over;
[0011] FIGS. 5A , 5 B illustrate exemplary sequences of operations to determine if contactors are in a closed or open state;
[0012] FIG. 6 illustrates an exemplary circuit to determine if contactors are in a closed or open state; and
[0013] FIG. 7 illustrates a further exemplary sequence of operations to determine if contactors are in a closed or open state.
DETAILED DESCRIPTION
[0014] In various embodiments disclosed herein, a pre-charge device and contactor test device are used to reduce the delay to switch between battery packs in a multiple battery pack system compared to delays required in prior-art techniques. The reduction in switchover delay provides many significant benefits, including, for example, improved electric/hybrid vehicle drivability and safety as an interruption in power during a critical time period is less likely. Moreover, battery life is improved because a) multiple battery packs are prevented from being connected at the same time, and b) the intrinsic capacitance of the vehicle load is prevented from becoming discharged, both of which could cause excessive current flow and damage to the battery system. While the foregoing benefits apply particularly to electric/hybrid vehicles, any system or apparatus which requires switchover between battery packs may benefit from the techniques described herein.
[0015] FIG. 2A illustrates one embodiment of a battery pack system with contactor test 240 and pre-charge 220 devices to reduce the time taken to switch between battery packs. The system is controlled by a battery management system (BMS) 270 . The vehicle management system (VMS) 280 communicates with the BMS via a controller-area network (CAN) bus and monitors and/or controls the vehicle load 260 . The BMS, shown in FIG. 2B , includes a processor, memory, and I/O block coupled together with an interconnect bus. The BMS is capable of executing the sequences of operations disclosed herein. One embodiment of the pre-charge device is a resistor with a relay that is controlled by the BMS. The resistance is calculated to a) allow current flow that can charge the intrinsic capacitance of the vehicle load 260 within a desired time limit, and; b) limit the current flow from the battery pack 210 below a maximum limit. An alternative embodiment of the pre-charge device could be a current source. The contactor test device 240 is used to determine if one or both of the contactors connected to a battery pack are either open or closed. In one embodiment, this information is used to prevent multiple battery packs being connected to the vehicle load at the same time. The diode 230 and diode contactor 225 are used to allow the depleted battery pack to provide a low level of power during the pre-charge period of switching between battery packs. A contactor may be any type of switching element including, for example and without limitation, a relay (or any other mechanical switch), a semiconductor device, or an electrically-isolating switching element.
[0016] FIG. 3 illustrates an exemplary sequence of operations used to switch between battery packs in a multiple battery pack system. At step 315 the process waits until the charge in the current battery pack (in this example pack 1 ) becomes sufficiently low that a pack switchover is required. At step 325 contactor NB (from FIG. 2A ) is closed to connect the negative terminals of the two battery packs. The diode protected positive contactor DC 1 is closed on the battery pack currently in use in step 330 . This allows current to continue flowing from the depleted battery pack but prevents any reverse current. At 335 the BMS monitors the vehicle power demand, and when it drops below a threshold (programmable based on the characteristics of the contactors and other factors), it opens Contactor 1 A in step 340 . This will cause the power draw to immediately switch to Contactor DC 1 225 (through the diode). Next in 345 , the contactor test device 240 is used to determine if Contactor 1 A has opened successfully. One embodiment of the contactor test device is shown in FIG. 6 described below.
[0017] At step 350 the vehicle is completely operating from power supplied through Contactor DC 1 which prevents any current from flowing into the Battery 1 through diode D 1 . The pre-charge for the next battery pack to be used (in this case pack N) is enabled to allow current to flow. This will allow the pack voltage to increase until it reaches the voltage of battery pack N.
[0018] As long as the vehicle continues to draw a lower level of power the pre-charge will be successful; however, if the vehicle starts drawing more power than the pre-charge circuit can accommodate, the pre-charge will be reset and the vehicle will return to operation using battery pack 1 . Different embodiments may have different pre-charge circuits that are capable of operating at different (higher or lower) levels of power drawn by the vehicle. This sequence will continue until the vehicle remains in a low power state long enough to fully pre-charge the pack to the pre-charge level of pack N (see FIG. 4 , described below). When the pre-charge level of pack N reaches a predetermined threshold (which may be stored in a plurality of programmable registers in the BMS) in step 355 , in this example defined as when the voltage at V load + reaches 90% of the battery pack N voltage (although other methods could be used to determine successful pre-charge), contactor NA is closed and the pre-charge for battery pack N is disabled in step 360 , allowing the pack to draw full power from pack N. The contactor test device is again used to determine if contactor NA has actually closed in step 365 . If contactor NA is determined to not be closed, then the sequence continues back to step 350 to repeat the pre-charge and contactor closing operations. The diode D 1 prevents energy from flowing from pack N into pack 1 . Next in step 370 contactors 1 B and DC 1 are opened. The state of contactors 1 B and DC 1 state is verified, again using a contactor test device, in step 375 . If both contactors are verified (or confirmed) to be open, the vehicle is then completely switched from battery pack 1 to battery pack N. Otherwise, the sequence loops back to attempt to open the contactors again.
[0019] FIG. 4 is a graph of the changing voltage across the vehicle load 260 as the switchover process progresses, as well as the effect of increasing the vehicle load during the pre-charge process. In the example shown, the connection to battery pack N completed when the V load voltage reaches the predetermined threshold, in this example 90% of the battery pack N voltage.
[0020] FIGS. 5A and 5B provide some exemplary sequences of steps to determine (or confirm or verify) if a contactor is open or closed. Referring to FIG. 5A , beginning at step 505 . First the contactor (in this case 1 A) is opened. Next the pre-charge for that contactor is enabled in step 515 . If the voltage across the vehicle load (V load ) rises as checked in step 520 , then it may be inferred that the contactor is open as the depleted battery pack would otherwise hold the voltage low against the pre-charge. This inference may be taken as a confirmation or verification for the purposes of battery pack switchover. Similarly a confirmation or verification that a contactor has been closed can be performed as shown in FIG. 5B . First the pre-charge is disabled in step 545 . Then the contactor (in this example contactor NA) is closed in step 550 . Next V load is measured over time (as the load changes) and evaluated for stability in step 555 . If the V load is stable, then the contactor is closed and the charged battery is providing power to the system.
[0021] FIG. 6 shows one embodiment of a circuit that detects whether contactors are in an open or closed state. The circuit consists of load A and load B, test switch A and test switch B and voltage sensors 510 to temporarily connect a load between the two terminals of the battery pack and detect current flowing through the load. One embodiment may use resistors for loads and MOSFETs for switches although other components with similar capabilities could be used.
[0022] FIG. 7 illustrates an exemplary sequence of operations that may be used to determine whether contactors are closed and thus implement contactor test 240 . Referring to both FIG. 6 and FIG. 7 , the sequence begins by closing test switch B in operation 720 . If voltage sensor 510 indicates that current is flowing through load B (i.e., a voltage drop greater than a predetermined or programmable threshold is detected), then it may be inferred that both contactors A and B are closed as no current would flow from the battery pack if both contactors A and B were open. Conversely, if voltage sensor 510 indicates that no or negligible current is flowing through load B, then processing continues with step 740 where test switch A is closed. If current then flows through load A as checked in step 750 , then contactor A is closed. Otherwise contactor A is open.
[0023] The embodiments described herein may be applied to any type of device that can store energy, rechargeable or non-rechargeable, including, but not limited to, alkaline, lithium-ion, nickel-cadmium, lead-acid, flow and atomic batteries, fuel cells, and capacitors.
[0024] In the foregoing description and in the accompanying drawings, specific terminology and drawing symbols have been set forth to provide a thorough understanding of the present invention. In some instances, the terminology and symbols may imply specific details that are not required to practice the invention. For example, the term “coupled” is used herein to express a direct connection as well as a connection through one or more intervening circuits or structures. Device or system “programming” may include, for example and without limitation, loading a control value into a register, one-time programmable-circuit (e.g., blowing fuses within a configuration circuit during device production) or other storage circuit within an integrated circuit device of the host system (or host device) and thereby control an operational aspect of the host system or establish a host system configuration. The terms “exemplary” and “embodiment” are used to express an example, not a preference or requirement. Signal paths that appear as single conductors may include multiple conductors and vice-versa, and components shown as being included within or forming part of other components may instead be disposed separately from such other components. With regard to flow diagrams and the like, the order of operations may be different from those shown and, where practical, depicted operations may be omitted and/or further operations added.
[0025] While the invention has been described with reference to specific embodiments thereof, it will be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope. For example, features or aspects of any of the embodiments may be applied, at least where practicable, in combination with any other of the embodiments or in place of counterpart features or aspects thereof. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
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A method for operating a battery system having multiple battery packs. The method includes decoupling the output of a discharged battery pack from the vehicle load, reducing the voltage between an output of a charged battery pack and the vehicle load prior to coupling the output of the charged battery pack to the vehicle load.
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FIELD OF THE INVENTION
The present invention relates to cellular radiotelephone systems and more particularly to a method and apparatus for allowing a new network with enhanced services to co-exist with an existing cellular network.
BACKGROUND OF THE INVENTION
Today's cellular networks are single-vendor systems with proprietary switch/cell-site interfaces that constrain network operators to grow by purchasing equipment from the same vendor that provided their initial equipment.
With dual-vendor capability, network operators can flexibly provide enhanced services by having the original vendor upgrade the existing system or by having another vendor install a new system which is phased in with the existing system.
Since the interface of a base station to a Mobile Telephone Switching Office (MTSO) is proprietary to that vendor, the introduction of a new network by another vendor often requires the installation of all new base stations and switching offices. Cellular network operators in major service areas are reluctant to completely replace their existing vendor's equipment with a new vendor's equipment. The network operators can perceive that a complete replacement would be too costly and too risky to undertake. Further, their system would remain a single vendor network. In order to make the transition as cost effective as possible, the new system must therefore operate in tandem with the old system. This is accomplished by having the new network overlay the old one.
However, since the two networks are incompatible, some problems can arise with call handling between subscribers. Each switching office will often have to handle calls according to the source, destination of each call and of course, the type of subscriber. As the cellular business matures, enhanced services will be more commonly available, and thus two types of subscribers can be identified in the network. Subscribers can be divided into premium or non-premium. The terms are used to differentiate between, for example, centrex integrated subscribers and subscribers to basic only cellular service. In this instance, basic and analog cellular subscribers are referred as non-premium, whereas centrex subscribers are referred to as premium subscribers. Thus, if a call originates from a non-premium subscriber, it is processed by the original switch.
Similarly, if a call is directed to a non-premium subscriber, the call is still processed by the original switch. However, if a call originates from a premium subscriber, it will be handled by the new switch.
Thus, if a new vendor equipment is to co-exist with the original vendor's equipment, subscribers must perceive no significant reduction in service quality or availability and cellular network operators must not be required to replace undepreciated capital equipment where it can be avoided.
There is accordingly a need for a system and a method for enhancing an existing cellular network such that a new system can operate in tandem with an existing cellular network without disrupting service to existing subscribers and without requiring the replacement of existing equipment.
SUMMARY OF THE INVENTION
The present invention provides to a service provider or network operator an ability to improve a cellular network without disrupting existing service. In particular, this is achieved by giving control of all dedicated control channels (CC) in each cell to a second switch. The second switch thereby is provided with the control of call set-ups, thus providing for more than one category of mobile subscriber.
Accordingly, it is an object of the present invention to provide to a network operator a method of operating a new cellular system in tandem with an existing system without disrupting service to existing subscribers.
Another object of the present invention is to provide a method of introducing a new cellular system in tandem with an existing system which will not require the replacement of existing equipment.
It is therefore an aspect of the present invention to provide a method of upgrading a cellular network having a plurality of cells with at least one base station in each cell and a mobile telephone switching office (MTSO) connected to a public network (PSTN), said MTSO servicing a first group of subscribers, comprising the steps of:
a) decoupling in and out trunks between said MTSO and said PSTN;
b) coupling in and out trunks between said PSTN and a second switching office (SSO);
c) coupling inter-office trunks from said SSO to said MTSO, and from said MTSO to said SSO;
d) placing, in each cell, base stations associated with said SSO with each base station associated with said MTSO; and
e) assigning for each cell a paging/access control channel associated with said SSO such that call set-up for said first and second group of subscribers is controlled by said SSO.
Another aspect of the present invention is to provide a method of upgrading a cellular network having a plurality of cells with at least one base station in each cell and a mobile telephone switching office (MTSO) connected to a public network (PSTN), said MTSO servicing a first group of subscribers, comprising the steps of:
a) decoupling incoming trunks from said PSTN to said MTSO;
b) coupling in and out trunks between said PSTN and a second switching office (SSO);
c) coupling inter-office trunks from said SSO to said MTSO, and from said MTSO to said SSO;
d) placing, in each cell, base stations associated with said SSO with each base station associated with said MTSO;
e) assigning for each cell associated with said MTSO, a modified paging/access control channel; and
f) assigning for each cell a paging/access control channel associated with said SSO such that call set-up for said first and second group of subscribers is controlled by said SSO.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of an existing single vendor cellular network;
FIG. 2 is an illustration of a multi-vendor cellular network according to a first embodiment of the present invention;
FIG. 3 is an illustration of a multi-vendor cellular network according to a second embodiment of the present invention;
FIG. 4 is a schematic flow chart of a method for upgrading an existing cellular network in accordance with a first embodiment of the present invention; and
FIG. 5 is a schematic flow chart of a method for upgrading an existing cellular network in accordance with a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, we have shown a cellular serving area 10, which provide a cellular service by means of a number of cell sites 11, 12, 13 and 14, which are located at various locations in serving area 10 according to the need of the service or network operator. Communication between a mobile subscriber 15 and the Mobile Telephone Switching Office (MTSO) 16 is done using one of the cell sites located near the subscriber. The interface 17 between the MTSO 16 and each cell-site is a proprietary interface, i.e. which operates on a protocol usable only with that vendor's equipment. The RF link 18 between mobile subscriber 15 and cell site 11 consist of the EIA-553 protocol which has been adopted as a standard for analog cellular networks or the IS-54 dual-mode standard. In and out trunks 19 are used to connect the MTSO 16 to the Public Switched Telephone Network (PSTN) 20. With this type of network architecture, the cellular network operator is limited to a single vendor for increasing the capacity of the network or providing enhanced services.
In the illustration of FIG. 2, a new vendor can provide additional or enhanced services to the existing network 10a with an overlay network 10b, by placing a Second Switching Office (SSO) 21 in control of the dedicated control channels (CCHs) in each cell, thereby, giving the SSO control of call set-ups. The MTSO retains most of the voice channels (VCHs). The SSO is assigned a few VCHs and the control channels (CCHs). This is accomplished by decoupling in/out trunks 19 of the MTSO 16 and coupling in/out trunks 22 from the SSO 21 to the PSTN 20. A number of inter-office trunks 23 are coupled from the SSO 21 to the MTSO 16 and from the MTSO 16 to the SSO 21. Each cell site base station 11a, 12a, 13a and 14a associated with the MTSO 16 is provided with second base stations 11b, 12b, 13b and 14b associated with the SSO 21. With this arrangement, wherein the CCHs are in the overlay network 10b, the SSO 21 controls the system by controlling the voice channel access by the mobiles.
In operation, any call to or from a mobile is initiated via signalling on the CCHs assigned to the SSO 21. The SSO 21 sets up and initially services all calls. For each call, the SSO decides whether to continue servicing the call or to hand "down" the call to the MTSO 16 via the interoffice trunks 23. For example, one criterion that could be used for hand "down" could be that any subscriber that has not subscribed to a premium service would be handed down for service by the MTSO 16. The industry standard for intersystem handoff (IS-41) is the basis for these hand "downs". Interim Standard 41 is the Cellular Radio Telecommunication Intersystem Operation Standard. The operation is best shown in FIG. 4.
In the illustration of FIG. 3, a new vendor can similarly provide additional or enhanced services to the existing network 10c with an overlay network 10d, by placing a Second Switching Office (SSO) 31 in control of the dedicated control channels (CCHs) in each cell, thereby, giving the SSO control of call set-ups. This is accomplished by decoupling the in trunk of the MTSO 16 and coupling only the out trunk 34 from the MTSO 16 to the PSTN. In/out trunks 32 from the SSO 31 are coupled to the PSTN 20. A number of inter-office trunks 33 are coupled from the SSO 31 to the MTSO 16 and from the MTSO 16 to the SSO 31. Each cell site base station 11c, 12c, 13c and 14c associated with the MTSO 16 is provided with a second group of base stations 11d, 12d, 13d and 14d associated with the SSO 31. With this arrangement, wherein the CCHs are in the overlay network 10d, the SSO 31 controls the system by controlling the voice channel access by the mobiles. The paging/access channel of the MTSO is set up either by removing the paging channel or by disabling that channel, such that only the access channel is in operation. In effect, the CCH of the MTSO are arranged such that no mobile will scan and lock onto any of paging channels of the MTSO to monitor for paging messages. This requirement can be met by setting the CCHs as described above, by provisioning the MTSO's access-only channels outside the dedicated 21 control channels or by provisioning the CCHs such that they are "mistuned" to operate on appropriate frequencies. Thus, the MTSO would operate what it believes were combined page/access control channels in the dedicated 21 CCHs in a way that all mobiles in the system would see as access-only CCHs.
In operation, the subscribers are divided into a set to be serviced by the SSO 31 and a set to be serviced by the MTSO 16. For example, calls from mobiles can originate either from a premium or a non-premium subscriber. When premium subscribers attempt to originate calls, the SSO 31 handles the call set-up on the dedicated CCHs and then services the call on its set of voice channels (VCHs). The SSO's VCs and the dedicated CCHs would be monitored by base stations 11d, 12d, 13d and 14d. When non-premium subscribers attempt to originate calls, the SSO intercepts the attempts on the dedicated CCHs, which as indicated above are now assigned to the SSO 31 from the MTSO 16, and sends back a "Directed retry" message on the dedicated CCH which causes the non-premium subscriber to re-attempt access, but this time on an access-only CCH controlled by the MTSO 16. The subscriber unit can re-attempt access by being instructed to retune to the particular CCH assigned to the MTSO. The MTSO then sets up and services these calls.
Incoming calls to a cellular subscriber (premium and non-premium) arrive from the PSTN at the SSO 31. Calls to premium subscribers are set-up by the SSO and serviced on one of the SSO's VCHs. Calls to non-premium subscribers are set-up by the SSO 31 and handed down to the MTSO 16 as follows. When the call to the non-premium subscriber reaches the SSO, the SSO simultaneously pages the called non-premium subscriber on its dedicated CCH and forwards the incoming call to the MTSO 16 via the interoffice trunks 33. The non-premium subscriber receiving the page message on the SSO's CCH responds to the SSO. At that time, the SSO instructs the non-premium subscriber to retry its page response access attempt on the access-only CCHs controlled by the MTSO 16. During this directed retry attempt by the non-premium subscriber, the MTSO has received the forwarded incoming call and has gone through its internal paging process and "sends out" a page message on the above mentioned "missing" or "mistuned" paging channel to the non-premium subscriber. When the subscriber's page response is received at the MTSO, which is really in response to the SSO's paging message, the MTSO proceeds to set up the call. Thus, the MTSO operates as before the upgrade, that is, as if it had control of the call set-up and service. The subscriber does not see any degradation in service and does not know whether calls are handled by the MTSO or the SSO. The above described operation is depicted in FIG. 5.
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A method of enhancing an existing cellular network is described such that a new system can operate in tandem with an existing cellular network without disrupting service to existing subscribers and without requiring the replacement of existing equipment. In particular, this is achieved by giving control of all dedicated control channels (CCHs) in each cell to a second switch. The second switch thereby is provided with the control of call set-ups, thus providing for more than one category of mobile subscriber. Some subscribers can be serviced by the existing switch and others by the second switch.
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BACKGROUND
[0001] Drilling offshore oil and gas wells includes the use of offshore platforms for the exploitation of undersea petroleum and natural gas deposits. In deep water applications, floating platforms (such as spars, tension leg platforms, extended draft platforms, dynamically positioned platforms, and semi-submersible platforms) are typically used. One type of offshore platform, a tension leg platform (“TLP”), is a vertically moored floating structure used for offshore oil and gas production. The TLP is permanently moored by groups of tethers, called tension legs, that eliminate virtually all vertical motion of the TLP. Another type of platform is a spar, which typically consists of a large-diameter, single vertical cylinder extending into the water and supporting a deck. Spars are moored to the seabed like TLPs, but whereas a TLP has vertical tension tethers, a spar has more conventional mooring lines.
[0002] Offshore platforms typically support risers that extend from one or more wellheads or structures on the seabed to the platform on the sea surface. The risers connect the subsea well with the platform to protect the fluid integrity of the well and to provide a fluid conduit between the platform and the wellbore.
[0003] Risers that connect the surface wellhead on the platform to the subsea wellhead can be thousands of feet long and extremely heavy. To prevent the risers from potentially buckling under their own weight or placing too much stress on the subsea wellhead, upward tension is applied, or the riser is lifted, to support a portion of the weight of the riser. Since offshore platforms often move due to wind, waves, and currents, for example, the risers are tensioned such that the platform can move relative to the risers. To that end, the tensioning mechanism often exerts a substantially continuous tension force on the riser.
[0004] Risers can be tensioned by using buoyancy devices that independently support the riser, which allows the platform to move up and down relative to the riser. This isolates the riser from the heave motion of the platform and eliminates any increased riser tension caused by the horizontal offset of the platform in response to the marine environment. This type of riser is referred to as a freestanding riser.
[0005] Hydro-pneumatic tensioner systems are another type of a riser tensioning mechanism. In this type of system, a plurality of active hydraulic cylinders with pneumatic accumulators is connected between the platform and the riser to provide and maintain the desired riser tension. The platform's displacement, which may be due to environmental conditions, that causes changes in riser length relative to the platform are compensated by the tensioning cylinders adjusting for the movement.
[0006] Floating platforms, which are used for deeper drilling and production, often encounter additional challenges, such as thermal expansion, due to the fact that the drilling extends into very high temperature formations where special drilling equipment may be required. At high temperatures, the riser, which extends from the sea floor, is subject to expansion and contraction. And that expansion and contraction of the production/drilling riser may result in undesirable movement, such as buckling, in response to temperature changes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A better understanding of the various disclosed system and method embodiments can be obtained when the following detailed description is considered in conjunction with the drawings, in which:
[0008] FIG. 1 is an illustrative, production riser system for elevated temperatures with completion landed;
[0009] FIG. 2 is an embodiment of an annular tensioner with castellated gathering fingers;
[0010] FIG. 3 is an illustrative, production riser system with production in operation at elevated temperatures;
[0011] FIG. 4 is an illustrative, production riser system with control lines running outside the annular tensioner space;
[0012] FIG. 5 is an illustrative offshore drilling system in accordance with various embodiments;
[0013] FIG. 6 is an illustrative drilling riser system including an outer riser with a nested internal riser; and
[0014] FIG. 7 is the drilling riser system of FIG. 6 with the inner riser installed within the outer riser.
DETAILED DESCRIPTION
[0015] The following discussion is directed to various embodiments of the invention. The drawing figures are not necessarily to scale. Certain features of the described embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of conventional elements may not be shown in the interest of clarity and conciseness. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure, including the claims, is limited to that embodiment.
[0016] Certain terms are used throughout the following description, and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function.
[0017] In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . . ” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis.
[0018] Disclosed herein is a system for conveying fluid from a subsea well to a floating platform. The system includes a subsea wellhead, and an outer tubing connected at a lower end and supported in tension at the upper portion by the floating platform. Inner tubing is also included. The inner tubing is connected at a lower end to the subsea wellhead and is dynamically supported in tension at an upper end by the outer tubing so that the inner tubing can move relative to the outer tubing.
[0019] An embodiment of the system c facilitate production of fluid from a subsea well to a floating platform. The system includes a subsea wellhead, a production riser connected at a lower end to the subsea wellhead and supported in tension at an upper portion by the floating platform. A production tubing, a production tree, and a tubing hanger are also included in this embodiment. The production tubing is connected at a lower end to the subsea wellhead and dynamically supported in tension at an upper end by the production riser so as to be capable of movement relative to the production riser. The production tree is fixed to the upper portion of the production riser. The tubing hanger is landed in and supported by the production tree with the production tubing being in fluid communication with the tubing hanger while being dynamically supported for movement relative to the tubing hanger.
[0020] FIG. 1 illustrates an embodiment of such a production riser for elevated production fluid temperatures. The production riser system includes a production riser 120 connected with a subsea wellhead (not shown). A production tubing 108 extends within the production riser 120 and is in fluid communication with the production fluids from the well. A dynamic tensioner 112 maintains the production riser 120 in tension as the floating platform 317 moves. The production riser system also includes a production tree 104 installed on the upper end of the production riser 120 . The production tree 104 control the flow of fluids into and out of the well, and can be a vertical or horizontal “spool” tree. As shown, the production tree 104 is a horizontal tree.
[0021] The production tree 104 supports a tubing hanger 102 that is in fluid communication with the production tubing 108 . And that production tubing 108 is dynamically supported for movement relative to the tubing hanger 102 , as explained below. The production tubing 108 further includes a slip connector 124 at a position along the length of the inner tubing. Although the slip connector 124 is shown near the upper portion of the riser system, the connector can be located in the center of the riser or even at the lower subsea portion of the production riser system.
[0022] The slip connector 124 includes an overshot tubing 125 that includes an open lower end and internal volume. A polished bore rod (PBR) 110 in fluid communication with the well below the overshot tubing extends into the internal volume of the overshot tubing through the overshot tubing's open lower end and is movable within the overshot tubing. The overshot tubing also includes a centralizer 127 for centering the overshot tubing within the production riser 120 . The overshot tubing also includes a dynamic seal 129 for sealing against the outside of the PBR as explained further below. The centralizer centralizes the overshot tubing within the production riser 120 for easier insertion of the PBR into the overshot tubing without damaging the overshot tubing's dynamic seal against the PBR.
[0023] The system for conveying fluids further includes an outer tubing with an internal shoulder, an inner tubing with an external shoulder, and an annular tensioner landed on both the outer tubing internal shoulder and the inner tubing external shoulder. The annular tensioner is movable to dynamically support the production tubing in tension. As shown in the embodiment of a production riser system, the annular tensioner 112 includes a tension plug 114 surrounding the production tubing with an outer diameter larger than the inner diameter of the production riser internal shoulder. The annular tensioner 112 also includes a tension piston 116 surrounding the production tubing with an inner diameter less than the outer diameter of the production tubing external shoulder. The tension plug 114 and tension piston 116 are located in the production riser and seal against the inside of the production riser and the outside of the production tubing to form a sealed chamber. The tension piston 116 is movable within the production riser with respect to the tension plug 114 from pressure in the sealed chamber as the production tubing moves relative to the production riser. Both the tension piston 116 and the tension plug 114 include castellated gathering fingers 235 a and 235 b for coupling to each other, as illustrated in FIG. 2 . The castellated gathering fingers on both the tension plug 114 and the tension piston 116 include an angled ramp area. These angled ramps gather the control lines inside the sealed chamber to avoid pinching as the tensioner plug 114 and the tensioner piston 116 come together.
[0024] As shown in FIG. 1 , the tension piston 116 , when initially installed, may rest on the tension plug 114 , and be designed to place the production tubing in tension. One option thus includes landing in tension. However, another option includes applying pressure to the annular tensioner 112 sealed chamber and holding that tubing 108 in tension.
[0025] The production riser itself could be several hundred to several thousand feet. The tension piston rests on the tension plug, which rests on tension joint that is supported by the dynamic tensioner on the platform. The top of the tension joint is pulled up, and the bottom of the tension joint is pushed down; and the tension joint body goes into tension, but sums to zero. The external tensioner setting is established to keep the external riser pipe 120 in tension. This is accomplished with sufficient tensioner setting to keep the production riser 120 in tension.
[0026] For installation, the production riser is attached to the subsea wellhead and set up in tension using the dynamic tensioner. The production tubing is then run in and attached to the subsea wellhead. When enough of the production tubing is installed, the annular tensioner components are installed and the production tubing is placed in tension. Completion related control lines 126 are run through the tension piston 116 , coil around the production tubing inside the sealed chamber and then exit the tension plug 114 . Penetrations are sealed with fittings, lines are continuous, and the coils allow the necessary movement up and down of the tension piston. The various control lines 126 are used to operate various valves in the permanently installed subsea piping.
[0027] Finally, the PBR is attached to the production tubing and the tubing hanger 102 and overshot assembly is lowered into the production tree allowing the overshot to swallow the PBR 110 . The blowout preventer is then removed, all control lines 126 are finalized, and tree 104 is capped.
[0028] FIG. 3 illustrates a production riser system operating with production fluid at elevated temperatures. Here, the tubing 308 has expanded in length due to heating. The overshot connector 324 helps to accommodate the expanded tubing 308 while maintaining the dynamic seal with the PBR. The annular tensioner sealed chamber pressure supply is at a level sufficient to move the tension piston upwards with the production tubing outer shoulder and thus hold the production tubing in tension despite the upward movement. Alternatively, a pressure supply may maintain the pressure in the sealed chamber so as to place enough force on the tension piston to keep the production tubing in tension. The necessary pressure in the sealed chamber may be determined based on measurements of a characteristic of the sealed chamber, such as pressure, temperature, or position of the production tubing.
[0029] There are multiple advantages to the presented invention. One main advantage is that the floating structure buoyancy needs are reduced, along with the tensioner system capacity. Normally, a subsea, wellhead tubing hanger carries significant tubing loads. Further, this system allows the external riser to stay in tension with standard external tensioner approach. This system may also be used to support a drilling riser with an inner pipe requirement. Overall, it is important to note that this exemplary system supports the inner pipe in tension, avoids compression, and avoids buckling by use of an the annular tensioner. Finally, all seals and annuli may be monitored from the floating structure deck.
[0030] As discussed above, there are various options for configuration and the use of multiple components. Another advantage of the present invention is the ability to employ several methods for not requiring the down hole lines to penetrate the annular tensioner space. The control lines would simply exit the tension joint, radially by several methods. FIG. 4 shows a method which could have a taller tension plug 414 with several radial line exits for hydraulic service. This solution does not address the optical line. This option does not require the use of orientation of the tension plug to the tension joint because each subsequent line is ported stacking up the plug. In other words, once the tension plug is in place, the tension plug porting and the tension joint porting would line up without orientation. A control, monitoring, and injection lines manifold 432 would be positioned upon the TLP deck 434 . An advantage of this embodiment would be the elimination of penetration through the annular tensioner space in the riser system, which normally would require numerous control, monitoring, or injection lines.
[0031] Another alternative would allow direct connection of the control lines, but also require orientation of the plug with respect to the tension joint. A port can be coupled directly to a control line. By “direct,” it is intended to include a connection or coupling between a control line and a port that does not requires annular seals that are used to seal annular zones. A control, monitoring, and injection lines manifold 432 would be positioned upon the TLP deck 434 . The advantage of this embodiment would be the elimination of penetration through the annular tensioner space in the riser system, which normally would require numerous control, monitoring, or injection lines. This could be a solution on dual barrier drilling riser or on elevated temperature production risers. As an added feature, the system will include control and other down-hole hydraulic and/or fiber-optic lines without sharing space with an annular tensioner feature.
[0032] Another embodiment is also included in the present invention. This embodiment is a drilling riser system connected to a wellhead located at a seafloor. The drilling riser system includes an external riser for a floating structure with an external tensioner keeping the external riser pipe in tension. The drilling riser system also includes an internal riser with an overshot slip connector and annular tensioner as described above. The drilling riser system is such that the outer and inner drilling risers allow passage of a drill bit and drill string through the riser to the subsea well.
[0033] Referring now to FIG. 5 , a schematic view of an offshore drilling system 500 is shown. The drilling system 500 may be of any suitable configuration. For example, the drilling system 500 may be a dry BOP system and include a floating platform 501 equipped with a drilling module 502 that supports a hoist 503 . Drilling of oil and gas wells is carried out by a string of drill pipes connected together by tool joints 504 so as to form a drill string 505 extending subsea from platform 501 . The hoist 503 suspends a kelly 506 used to lower the drill string 505 . Connected to the lower end of the drill string 505 is a drill bit 507 . The bit 507 is rotated by rotating the drill string 505 and/or a downhole motor (e.g., downhole mud motor). Drilling fluid, also referred to as drilling mud, is pumped by mud recirculation equipment 508 (e.g., mud pumps, shakers, etc.) disposed on the platform 501 . The drilling mud is pumped at a relatively high pressure and volume through the drilling kelly 506 and down the drill string 505 to the drill bit 507 . The drilling mud exits the drill bit 507 through nozzles or jets in face of the drill bit 507 . The mud then returns to the platform 501 at the sea surface 511 via an annulus 512 between the drill string 505 and the borehole 513 , through subsea wellhead 509 at the sea floor 514 , and up an annulus 515 between the drill string 505 and a riser system 516 extending through the sea 517 from the subsea wellhead 509 to the platform 501 . At the sea surface 511 , the drilling mud is cleaned and then recirculated by the recirculation equipment 508 . The drilling mud is used to cool the drill bit 507 , to carry cuttings from the base of the borehole to the platform 501 , and to balance the hydrostatic pressure in the rock formations. Pressure control equipment such as blow-out preventer (“BOP”) 510 is located on the floating platform 501 and connected to the riser system 516 , making the system a dry BOP system because there is no subsea BOP located at the subsea wellhead 509 . With the pressure control equipment at the platform 501 , the dual barrier requirement may be met by the riser system 516 including an external riser with a nested internal riser.
[0034] As shown in FIG. 6 , the external riser 600 surrounds at least a portion of the internal riser 602 . The riser system is shown broken up to be able to include detail on specific sections but it should be appreciated that the riser system maintains fluid integrity from the subsea wellhead to the platform.
[0035] A nested riser system requires both the external riser 600 and the internal riser 602 to be held in tension to prevent buckling. Complications may occur in high temperature, deep water environments because different thermal expansion is realized by the external riser 600 and the internal riser 602 due to different temperature exposures-higher temperature drilling fluid versus seawater. To accommodate different tensioning requirements, independent tension devices are provided to tension the external riser 600 and the internal riser 602 at least somewhat or completely independently.
[0036] In this embodiment, the external riser 600 is attached at its lower end to the subsea wellhead 509 (shown in FIG. 5 ) using an appropriate connection. For example, the external riser 600 may include a wellhead connector 604 with an integral stress joint as shown. As an example, the wellhead connector 604 may be an external tie back connector. Alternatively, the stress joint may be separate from the wellhead connector 604 . The external riser 600 may or may not include other specific riser joints, such as riser joints with strakes or fairings and splash zone joints 608 . This embodiment also includes a surface BOP 660 . Other appropriate equipment for installation or removal of the external riser 600 and the internal riser 602 , such as a riser running tool 650 and spider 652 may also be located on the platform.
[0037] As shown in FIG. 7 , the drilling riser system includes the external drilling riser 700 supported by the dynamic tensioner on the platform. Extending within the external riser 700 is an internal drilling riser 702 . Also included are the external shoulder on the internal drilling riser, the internal shoulder on the external drilling riser 700 , and the annular tensioner. The annular tensioner 712 operates in a similar manner to the annular tensioner described above and the discussion of its operation will not be repeated.
[0038] Instead of a production tree as shown in the production system, the external riser and the internal drilling riser of the drilling riser system terminate in a surface drilling wellhead 709 which is connected to a blowout preventer 710 on the drilling platform. Appropriate connections for circulating drilling fluid, such as a diverter (not shown) that accepts the drill string for insertion through the internal drilling riser, are attached to the top of the BOP 710 .
[0039] Also included as part of the internal drilling riser is the overshot slip connector 711 using the overshot tubing and PBR 713 . As discussed above, the overshot slip connector allows for the movement of the internal drilling riser relative to the external riser due to thermal expansion. The annular tensioner maintains the internal riser in tension during such movement so as to avoid buckling.
[0040] Other embodiments of the present invention can include alternative variations. These and other variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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The riser system of the present invention includes an external production riser for floating structures with interfaces to the dry and subsea wellheads, internal tieback riser with a special lower overshot/slipping connector for elevated temperatures. The seals can be metallic and/or non-metallic dynamic seals. Special centralizing pipe connectors and a special subsea wellhead tubing hanger are also included. This riser system avoids the penalty of pipe within pipe differential thermal growth and the resulting unwanted effects on the floating structure. This is accomplished by allowing an overshot sealing slipping connector to swallow an expanding polished rod as thermal conditions cause pipe elongation axially. When elevated temperatures fall to ambient the opposite occurs as the pipe shrinks axially. Alternatively, a system is possible where a two pipe drilling riser is needed. The internal pipe in this case would be an inner riser rather than a tubing string.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 08/110,178, filed on Aug. 20, 1993, now abandoned.
which is a continuation-in-part of Ser. No. 07/804,135, filed Dec. 6, 1991, now abandoned entitled: "FRANGIBLE SEMICONDUCTOR WAFER DICING METHOD WHICH EMPLOYS SCRIBING AND BREAKING".
FIELD OF THE INVENTION
This invention relates to improvements in the handling of substrates which are easily broken and, more particularly, to apparatus and a method for scribing and breaking substrates such as semiconductor wafers, thin glass and the like.
BACKGROUND OF THE INVENTION
As is well known, semiconductor wafers are scribed along specific lines and thereafter separated along such lines to divide the wafer into semiconductor chips. Such division lines can be scribed with a diamond-pointed scribing tool or cut by a laser or saw. However, when the lines are scribed or partially cut, the wafer is not immediately separated into its individual pieces but must be broken after scribing has occurred.
Many attempts have been made to provide apparatus for breaking a semiconductor wafer into individual pieces with each piece representing a particular semiconductor chip. For the most part, these attempts have been unsatisfactory for one or more reasons. Specifically, the yield of a wafer using conventional techniques has been relatively low, and the loss of a large number of semiconductor chips from a given wafer represents a large loss in profits which could be realized if the yield were greater.
Breaking a scribe line is implemented by putting it in tensile strain. The point or bottom of the vertical crack under the scribe line will start experiencing molecular bond failures; slowly at first and increasing in an avalanche fashion. When the bond failure becomes quite rapid, the strain energy required to feed the failing is minuscule in relation to the tensile strength of the material. When the rapid bond failure initiates, it commonly starts at the edge of the wafer. The strain induced around the unbroken scribe line is released as the scribe line starts to fail and supplies the necessary energy to feed the break along the scribe line.
Until this invention, all known breaking methods and apparatus applied the tensile breaking strain in a mass fashion; e.g. causing the wafer to conform to a convex cylindrical section parallel to the scribe lines, or causing a single scribe line to bend about an edge in a guillotine fashion. All of these techniques attempt to break a scribe line instantly. Since scribe lines always break in a serial fashion from point A to point B, not instantaneously, the strain energy built up in the material affects the completion of the break. Usually, this residual strain energy is too much and ill-applied to achieve a perfect break. The excess applied strain contributes to chipping, edge degradation and skew (off scribe line) breaks.
Additionally, the traditional breaking methods always touch the entire surface of the wafer. With the introduction of "air-bridge" circuits (very thin micro-conductors, suspended over other conductors with the air space between acting as an insulator), breaking wafers has become more difficult because the air bridges are very fragile and must not be touched or contaminated during the breaking operation. Because of the drawbacks associated with conventional breaking techniques, a need has continued to exist for some time for an improved breaking apparatus and method to permit high yields yet provide for simplicity in operation without interference with the scribing step. The present invention satisfies this need because not only does it apply a limited (and adjustable) strain just necessary to drive the bond failures along the scribe line, but it also integrates breaking with scribing and thus can locate breaking forces outside the active circuit areas, which is normally the wafer separation grid area.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus and method for handling frangible substrates, such as semiconductor wafers, thin glass, etc., wherein a substrate can be scribed and immediately thereafter broken into rows of strips then subsequently scribed and broken into individual chips (or "die", the entire operation generally referred to as "scribing and dicing"). The scribing and breaking steps can be achieved while realizing high yield and provide for almost immediate breaking after scribing without interference with the scribing of the substrate.
To this end, the present invention provides the breaking of a substrate along the scribed lines on a substrate in a translating three-point beam bending system wherein beam bending forces are applied at two locations in a translating fashion on one side of the wafer and at a third point on the opposite side of the wafer between the first two points to permit the forces to be exerted on the substrate in breaking relationship thereto along the scribed lines.
The apparatus of the present invention further includes, in a preferred embodiment of the breaking means, a rotatable break wheel that is selectively engageable via its two profiles with the substrate on opposite sides of a line scribed by a scribing tool, the break wheel and tool being movable relative to the substrate preferably along straight lines. Thus, the wheel and tool can move relative to and along a surface of the substrate or, alternatively, the substrate can move while the wheel and tool remain stationary.
Version One:
In the breaking of the substrate, the break wheel profiles, when they engage one surface of the substrate, provide two of the three points of a three-point beam bending system relied upon in the present invention for breaking the substrate along a scribed line. The third point of the three-point beam bending mode is provided by a fixed abutment or support, preferably a mandrel, having an inclinable surface. The left wheel profile is positioned so it is incident on the portion of the substrate supported by the inclinable mandrel. The right wheel profile is positioned so it is incident on the cantilevered portion of the substrate. Since the downward travel of the break wheel is limited by the left profile engaging the supported portion of the wafer, the maximum strain induced around the unbroken portion of the scribe line is adjusted by changing the angle of the inclinable mandrel.
Version Two:
A second version of this breaking method uses a break wheel with three profiles. The center profile engages the substrate directly on the scribe line, the left and right profiles are positioned as in version one. The angle of the inclinable mandrel is set to the angle of the contact line of the left and center profiles. This angle is determined by the difference in diameter of the center and outer profiles of the break wheel, the center profile diameter always being less than either outer profile diameter. In this version of the invention, the downward travel of the break wheel is limited by the left and center profiles engaging the supported substrate. Therefore the maximum strain induced around the unbroken portion of the scribe line is limited by the contact line angles of the center and outer break wheel profiles built into the break wheel.
Version Three:
A third version of this breaking method uses a combination of the techniques used in versions one and two above. Again, a three profile break wheel is used as in version two, except that it is shifted slightly to the right, so that the center profile is just to the right of the inclinable mandrel, and it engages the substrate on the cantilevered portion of the substrate. As in version one, the left profile engages the unbroken substrate over the inclinable mandrel, thus limiting the break wheel's downward travel, so the angle of the mandrel sets the maximum strain induced around the unbroken scribe line.
As the substrate breaks along the scribe line, the center wheel profile pushes the newly broken portion of the substrate down, causing a shearing action to take place between the unbroken and newly broken portions of the substrate. This helps shear any backside metallization of the substrate. Other breaking techniques fail to address the issue of ductile, backside metallization, which generally leave the wafer in a condition where the chips are broken from each other, yet still attached via the backside metal (generally referred to as "gold hinge").
Version Four:
A fourth version of this breaking method is used where the separation grid of the substrate is not in the same plane of the rest of the substrate, as in wafers where large contact "bumps" are part of the active circuit area. Here the wheel setup is the same as in version two, with the center wheel profile engaging the substrate directly over the scribe line. The inclinable mandrel is replaced with a fixed narrow blade that fits between the bumps on the substrate.
Since the center wheel profile is limited in its downward travel by the substrate supported on the blade, the breaking strain is controlled by the contact angle between the center and outer profiles of the break wheel.
Version Five:
A fifth version of this breaking method uses a break wheel with a compliant outer surface. The break wheel has a relatively rigid mounting core structure, an intermediate compliant layer preferably fabricated from a foam material, and an outer sheath fabricated from a pliant material for retaining the intermediate layer on the core. In use, after the scribe line is formed, the wheel is lowered onto the top surface of the substrate with the compliant outer surface in contact with the top surface of the substrate in a region which straddles the scribe line. The wheel is manipulated along the scribe line to provide the tensile strain required to break the substrate along the scribe line.
The invention can form part of a wafer scribing and dicing machine which is conventional in construction. The scribing tool of such a machine reciprocates relative to the substrate to be scribed. The substrate is scribed as the scribe tool engages the substrate and moves in one direction. Then the tool is disengaged from the substrate, the break wheel engages the substrate and the wheel is moved to the opposite side of the wafer, separating the wafer along the scribed line. Then the wheel is disengaged from the substrate and the wafer is indexed laterally and incrementally while both scribe tool and break wheel are disengaged from the substrate.
The break wheel is mounted on an arm coupled to the machine and preferably movable with the scribe tool back and forth past a substrate to be scribed and broken. The drive means for moving the tool back and forth can also be the drive means for the arm carrying the wheel. The arm carrying the wheel is independently raised and lowered with respect to the scribe tool and is lifted from the substrate after a single pass of the wheel relative to the substrate in breaking relationship thereto. The wheel can move and operate with the mandrel as breaking means as a function of the motion of the scribe tool itself, or the break wheel can operate with the mandrel in a reciprocal fashion from the motion of the scribe tool.
The primary object of the present invention is to provide a substrate breaking apparatus and method suitable for use with a substrate scribing tool wherein the breaking means comprises a three-point beam bending system which serves to apply forces to a substrate scribed by the tool to break the substrate along the scribe lines thereof while the substrate is held, yet the substrate can be moved incrementally and transversely to the direction of movement of the scribe tool, whereby an entire substrate can be broken along a plurality of scribe lines to thereby simplify the division of the substrate into small pieces.
Another object of the present invention is to provide an apparatus and methods of the type described wherein the breaking of a substrate can be accomplished immediately after a scribe line has been formed in the substrate, whereby the present invention is suitable for scribing and breaking a semiconductor wafer into individual semiconductor chips.
Other objects of the present invention will become apparent as the following specification progresses, reference being had to the accompanying drawings for an illustration of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of two-profile break wheel engaging a substrate;
FIG. 2 is a front elevational view of three-profile break wheel engaging a substrate;
FIG. 3A is a front elevational view of three-profile break wheel with center profile shifted to the right;
FIG. 3B is a close-up of the view of FIG. 3A;
FIG. 4A is a front elevational view of three-profile break wheel with the inclinable mandrel replaced with a narrow blade;
FIG. 4B is a close-up of the view of FIG. 4A;
FIG. 5 is a top elevational view of the scribing machine and breaking means thereon, showing the relationship of x-axis (incremental motion of substrate) and y-axis (linear translation system for scribe tool and break wheel);
FIG. 6 is a side view of the scribing machine, showing relationship of the y-axis and the z-axis (independent raising and lowering of scribe tool) and the break wheel to engage a substrate;
FIG. 7 is a front elevational view of a compliant break wheel engaging a substrate; and
FIG. 8 is a view similar to FIG. 7 illustrating the compliant break wheel in section.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The scribing and dicing apparatus of the present invention is broadly denoted by the numeral 10 and is shown in FIGS. 5 and 6. Apparatus 10 includes a base 12 for supporting a linear translation system 14 to which is coupled a scribe tool 16 for scribing a semiconductor or other wafer 18 mounted on a stretchable adhesive sheet 20 carried by a circular hoop or any other suitable conveyance mechanism 22 coupled in some suitable manner to base 12. The wafer 18 is adhesively bonded to the upper surface of the adhesive sheet 20, and the wafer is scribed by tool 16 as the tool moves under the influence of linear translation system 14 in one direction, such as to the left when viewing FIG. 6. As it moves to the left, the scribe tool scribes a line 24a (FIG. 5) as the tool 16 moves over the wafer 18 in one direction. After a line 24 has been scribed by the tool 16, the linear translation system 14 is caused to lift tool 16 above the wafer, then the tool is returned to its initial starting position or to the right when viewing FIG. 6 where the tool is in a position to scribe the next line. During a pause in the forward most travel to the right (when viewing FIG. 6) of the tool, the hoop 22 and sheet 20 are indexed by an indexing means 26 which will cause the sheet and hoop to incrementally move to the right when viewing FIG. 5 so as to position the tool 16 in a proper location for scribing the next scribe line 24.
The tool continues to scribe wafer 18 until all of the lines 24 parallel to line 24a shown in FIG. 5 have been scribed. After this has occurred, the hoop and sheet 20 and 22 are then rotated through an angle of 90° so that the wafer 18 will be in a position to be scribed by the tool along lines 28 which are perpendicular to lines 24.
The foregoing explanation relates to a scribing machine which is conventional in construction and operation. In the past, such a conventional machine was used merely to scribe a wafer, following which the scribed wafers would be removed from the machine and handled so as to separate the die or chips 25 formed by the formation of the perpendicular scribe lines 24 and 28 (FIG. 5). A typical scribing machine of conventional construction is one made and sold by Loomis Industries of St. Helena, Calif.
A breaking unit 30 is associated with the scribing part of apparatus 10 and unit 30 is provided to cause breaking of a column of chips on wafer 18 after a scribe line has been formed in the wafer. The breaking means cooperates with the stretchable adhesive sheet 20 which retains the chips on the sheet until the chips are removed one by one such as by a vacuum pick up device, where the chips are transferred to a point of use, such as another substrate for mounting a chip in a position to be wire bonded or the like.
Breaking unit 30 includes a break wheel arm 32 having a shaft 34 extending laterally therefrom. A break wheel 36 is mounted on the shaft and has bearings 37 mounting the wheel for rotation on shaft 34. The break wheel is held by a nut 38 threaded on the outer end 40 of the shaft 34, the nut bearing against the wheel for compressing a spring 42 which biases the wheel away from the break wheel arm 32. Several embodiments of wheel 36 are hereinafter described, the first embodiment being shown in FIG. 1 and other embodiments being shown in FIGS. 2, 3A, 4A, 7 and 8.
The break wheel arm 32 is pivotally mounted on an axle 44 (FIG. 5) for rotation about a generally horizontal axis, the axle being mounted on the linear translation system 14 in some suitable manner so that arm 32 can move up and down around the axle 44.
A fluid piston and cylinder actuator 46 (FIG. 5) is used to pivot the arm 32 in a counter-clockwise sense when viewing FIG. 6 so that the break wheel 36 (FIG. 1) can clear the wafer when the break wheel is to be returned to a starting position with respect to the scribe tool 16. As the arm 32 pivots upwardly with reference to FIG. 6, it carries break wheel 36 upwardly as well since the break wheel is mounted on the shaft 34.
Also associated with breaking means 30 is an elongated mandrel 48 which is rotatably carried by a bracket 50 coupled with base 12 in any suitable manner. An adjustment screw 52 permits the mandrel to be rotated about its central axis, said axis being defined by the edge 56 (FIG. 1) and being partially surrounded by the semicylindrical outer periphery 54 of the mandrel. A mandrel 48 has, adjacent to break edge 56, a break plane surface 58 which extends from the edge 56 to the outer periphery 54 as shown in FIG. 1.
The mandrel break plane surface 58 normally engages the lower surface of sheet 20 and the wafer 18 rests on sheet 20 and is supported by the lower break plane surface 58 as shown in FIG. 1.
Break wheel 36 has a pair of wheel profiles or profile members 60 and 62, each having a pair of sides 64 which converge to an outer, flat end face 66 which engages the wafer 18. The left hand member 60 engages the wafer in the unscribed portion thereof on one side of a scribe line 24; whereas, the other or right hand member 62 engages the wafer over a scribe line 24. Depending upon the angle of plane surface 58, a greater or lesser amount of strain or downward force is applied to the wafer to break the wafer as the wheel rotates about the central axis of shaft 34.
In the first embodiment of the wheel as shown in FIG. 1, the break wheel profile members 60 and 62, when they engage the upper surface of the substrate provide two of the three points of a three-point beam bending system for breaking the substrate along a scribed line. The third point of the three-point beam bending mode is provided by mandrel 48, specifically surface 58 thereof which is inclined. The profile member 60 is positioned so that it is incident on the portion of the substrate supported by the surface 58 of mandrel 48. Since the downward travel of the break wheel is limited by the left profile member 60 engaging the supported portion of the wafer, the maximum strain induced around the unbroken portion of the scribed line is adjusted by changing the angle of the inclined surface 58. This is achieved by adjusting screw 52 or some other means for pivoting the mandrel 48 about its central axis relative to bracket 50.
In the use of the embodiment of FIG. 1, wafer 18 is held on the upper surface of adhesive sheet 20 in the manner shown in FIG. 1. Sheet 20 is held taut by hoop frame 22 (FIG. 6) and the sheet is mounted on the upper plane surface 58 of mandrel 48 (FIG. 1).
With wafer 18 aligned transversely along the x-axis (FIG. 5) and rotationally about the θ axis (FIG. 5), the separation grid channel and the most recent scribe line 24 are parallel and superimposed over break edge 56 of mandrel 48. The break edge 56 is at the center of rotation of mandrel 48 to assure break edge 56 will be stationary during adjustment of inclinable surface 58 by way of adjusting of screw 52.
As shown in FIG. 1, the last scribed line 24 extends longitudinally in the direction of movement of the break wheel 36. The traversing step is accomplished by actuating linear translation system 14 (FIG. 6) which conveys the scribe tool 16 and break wheel system 30 such that the line is scribed in the wafer by the tool 16 as the wheel is elevated above and spaced above the wafer during movement to the left when viewing FIG. 6.
Typically, the wheel is lowered onto the wafer when the wheel moves from left to right and as the tool also moves from left to right in an elevated position above the wafer. Thus, during the scribe operation, the breaking wheel is out of contact with the wafer; whereas, during the return of the tool in an elevated position to its starting position, the break wheel is lowered and engages the wafer for breaking the wafer along the previously formed scribe line 24 as the break wheel 36 moves from left to right when viewing FIG. 6.
In the FIG. 1 embodiment, tensile strain is created transversely across the scribe line 24 by pushing wafer 18 on opposite sides of scribe line 24 with break wheel profile members 60 and 62. Members 60 and 62 roll across the wafer parallel to the last scribe line 24 as the profiles are conveyed by the linear translation system 14, causing tensile strain across the scribe line to travel along the length of the scribe line 24.
The maximum tensile strain induced across the scribe line 24 is adjusted by changing the angle of break plane surface 58 of mandrel 48. When surface 58 is rotated counterclockwise around edge 56, wheel profile members 60 and 62 bend the wafer more about the scribe line 24 and thus induce more tensile strain across the scribe line 24 prior to the breaking of the scribe line 24. Conversely, the tensile strain is reduced when surface 58 is rotated clockwise around break edge 56 by screw 52. In effect, the maximum tensile strain is adjusted across scribe line 24 so that failure occurs along line 24 directly between the break wheel profile members 60 and 62 or a short distance in front of break wheel motion.
FIG. 2 shows another embodiment of the breaking wheel of the present invention, the break wheel being denoted by the numeral 36a. Wheel 36a differs from wheel 36 (FIG. 1) in that wheel 36a has three annular profile members 60, 62 and 63 associated with it, member 63 being between members 60 and 62. Again, a wafer 18 is mounted on the adhesive portion of sheet 20, and the sheet is held taut by hoop 22 (FIG. 6) and is held over mandrel 48.
Break edge 56 of mandrel 48 is at the center of rotation of the mandrel 48 to assure break edge 56 is stationary during adjustment of inclinable plane surface 58. Adjustment can be achieved by a screw such as screw 52 (FIG. 1).
The scribe line 24 traverses entirely a separation grid channel which is located over break edge 56 of the mandrel 48. The movement of the wheel 36a and wheel arm 32 is accomplished by linear translation system 14 (FIG. 6) which conveys scribe tool 16 and break wheel system 30 including arm 32.
Tensile strain is created transversely across the scribe line 24 by pushing wafer 18 on opposite sides of scribe 24 with break wheel profiles 60 and 62. Break wheel profile members 60 and 62 roll across the wafer 18 parallel to scribe line 24 as they are conveyed by the linear translation system 14 causing tensile strain across scribe line 24 to travel along the length of the scribe line 24.
Tensile strain is limited by the center profile member 63 of the wheel 36a and also by the left profile member 60 engaging the upper surface of the wafer 18 over break plane surface 58 of mandrel 48, thus limiting downward travel of break wheel 36a. The break plane surface 58 is equal to the angle δ which is the contact angle between the center profile member 63 and left profile member 60. The maximum tensile strain developed is a function of the angle δ which, in turn, is a function of the diameter of the center profile member 63 in relation to the diameters of outer profile members 60 and 62. The break wheel 36a is made so that the diameter of the left profile member 60 is equal to the diameter of center profile 63 plus 2D1 tan (δ). The diameter of the right profile member 62 is equal to the diameter of the center profile member 63 plus 2Dr tan (δ).
Angle δ is chosen so that failure occurs between break wheel profiles 60 and 62 or a short distance ahead of break wheel motion. Typically, the angle of break plane surface 58 is adjusted to equal angle δ so that the left wheel profile member 60 and center profile member 63 engage the substrate 18 simultaneously. If the surface break plane 58 is adjusted to an angle less than δ then the downward travel of the break wheel is limited only by left profile member 60, so that the maximum induced tensile strain across the scribe line 24 is reduced. If the surface break plane 58 is adjusted to more than angle δ, then the downward travel of the break plane wheel is still limited by center profile member 63 so that the maximum induced tensile strain across scribe line 24 is still equal to the strain developed when surface break plane angle surface 58 is set to angle δ.
FIGS. 3A and 3B show another form of break wheel 36b which is used if the back side or bottom side of wafer 18 has a coating of ductile metallization or the ductile material that does not break easily with the substrate, thereby making the substrate prone to "gold hinge". In such a case, the wheel 36b is used and such wheel uses a group of three profile members 60, 62 and 63, with the central profile member 63 being offset to the right of the break edge 56 of mandrel 48.
In using the embodiment of FIG. 3A, wafer 18 is again held on a stretchable sheet 20 as described above with the other embodiments. Sheet 20 is held taut by hoop frame 22 over mandrel 48.
Wafer 18 is aligned transversely along the x-axis (FIG. 5) and rotationally about the θ axis (FIG. 5) so that separation grid channel and the most recent scribe line 24 are parallel and superimposed over break edge 56 of mandrel 48. The break edge 56 is at the center of rotation of mandrel 48 to ensure break edge 56 is stationary during the adjustment of angle adjustment of the break plane surface 58 of the mandrel.
Scribed line 24 traverses entirely a separation grid channel which is located over break edge 56. The movement of the tool 16 is accomplished by linear translation system actuator 14 (FIGS. 5 and 6) which convey scribe tool 16 and break wheel system 30 to the left and then to the right when viewing FIG. 6.
Tensile strain is created transversely across scribe line 24 by pushing wafer 18 on opposite sides of scribe line 24 with break wheel profile members 60 and 62. Members 60 and 62 roll across wafer 18 parallel to scribe line 24 as they are conveyed by the translation system 14, causing tensile strain across the scribe line to travel along the length of scribe line 24.
The maximum tensile strain induced across the scribe line 24 is adjusted by changing the angle of the break plane surface 58 of the mandrel 48. When surface 58 is rotated counterclockwise around break edge 56, profile members 60 and 62 bend the wafer more about scribe line 24 and thus induce more tensile strain across the scribe line 24 prior to scribe line 24 breaking. Conversely, the tensile strain is reduced when break plane surface 58 is rotated clockwise around break edge 56.
The maximum tensile strain across scribe line 24 is adjusted so that failure occurs along scribe line 24 directly between break wheel profile members 60 and 62 or a short distance in front of break wheel motion. As the break occurs along the scribe line 24, the newly broken strips or dice 25 are pushed down by center profile 63, thus creating a shearing action between the newly broken strip or die 25 and the unbroken substrate 18. This shearing action cuts and separates the backside metallization directly under scribe line 24.
As in the first embodiment, the left profile member 60 of the embodiment of FIG. 3a engages the unbroken substrate 18 over the inclinable mandrel surface 58, thus limiting the break wheel downward travel so that the angle of the mandrel break plane surface 58 sets the maximum strain induced around the unbroken scribe line. As the substrate 18 breaks along the scribe line, the center wheel profile member 63 pushes the newly broken strip or die down, causing a shearing action to take place between the unbroken substrate 18 and newly broken portions 25. This helps to shear any backside metallization. Other breaking techniques fail to address the issue of ductile, backside metallization, which generally leaves the wafer in a condition where the chips are broken from each other yet still attached by a way of the backside metal, generally referred to as "gold hinge".
In the fourth embodiment of the present invention as shown in FIGS. 4A and 4B, the separation grid of the substrate is not in the same plane as the rest of the substrate, as in wafers where large contact "bumps" are part of the active circuit area. In this embodiment, the breaking wheel 36c is the same as in the second embodiment with the center wheel profile member 63 engaging the substrate 18 directly over the scribe line 24. The mandrel 48 is replaced with a fixed narrow blade 49 which fits between the bumps on the substrate. Since the center wheel profile is limited in this downward travel by the substrate supported on the blade 49, the breaking strain is controlled by the contact angle between the center and outer profile members of the break wheel.
The substrate 18 is sometimes formed with relatively large contact bumps 21 in active circuit areas so that the separation grid is not in the same plane as the rest of the substrate. Typically, the substrate is not able to seat properly on break plane surface 58 of mandrel 48 due to the unevenness of the contact plane 21. In this case, a three profile break wheel is used as in the second embodiment except that the mandrel 48 in the second embodiment is replaced by a fixed narrow blade 49 in the fourth embodiment with the blade being operable to fit between the contact areas as shown in FIG. 4B.
In use, the fourth embodiment includes a wafer 18 held on a stretchable adhesive sheet 20. The sheet is held taut by hoop frame 22 over fixed narrow blade 49 as shown in FIG. 4A. Wafer 18 is aligned transversely along the x-axis (FIG. 5) and rotationally about the θ axis (FIG. 5) so that separation grid channel and most recent scribe line 24 are parallel and superimposed over fixed narrow blade 49.
The scribe line 24 traverses entirely a separation grid channel which is located over fixed narrow blade 49. The traversing operation is accomplished by linear actuator 14 which conveys the scribe tool 16 and break wheel system 30 in one direction over the substrate.
Tensile strain is created transversely across the scribe line by pushing wafer 18 on opposite sides of scribe line 24 with break wheel profiles 60 and 62. These two members 60 and 62 roll across wafer 18 parallel to scribe line 24 as they are conveyed by the translation system 14, causing tensile strain across scribe line 24 to travel along the length of scribe line 24.
Tensile strain is limited by a center profile 63 engaging wafer surface 18 over fixed narrow blade 49, thus limiting downward travel of break wheel 36c. The maximum tensile strain developed is a function of the angle δ which in turn is a function of the diameter of the center profile 63 in relation to the outer profile members 60 and 62. Break wheel 36c is made so that the diameter of the left profile member 60 is equal to the diameter of the center profile 63 plus 2 d1 tan (δ). The diameter of the right profile member is equal to the diameter of center profile member 63 plus 2 dr tan (δ). Angle δ is chosen so that the failure occurs between break wheel profile members 60 and 62 or a short distance ahead of break wheel motion.
FIGS. 7 and 8 illustrate another embodiment of the invention employing a break wheel with a compliant surface for applying downward pressure on the top surface of the substrate over a region which encompasses the scribe line along which the wafer is to be broken. With reference to FIG. 7, a compliant break wheel 70 is arranged on shaft 34 and held in place in the same manner as the break wheels described above. As best shown in FIG. 8, break wheel 70 has a relatively rigid annular core member 72 with an inner diameter dimensioned to be snugly received about the outer diameter of the reduced diameter portion of wheel support 74. Core 72 is fabricated from a magnetizable material in the preferred embodiment, so that the wheel 70 is magnetically attracted to a magnetic flange portion 76 of support 74. Other mechanical mounting arrangements may be employed, as desired. A compliant layer 78 is attached to core 72, preferably by means of a pliant layer 80 of heat shrinkable tubing, which is shrink-fitted to the outer surface of core 72 at the ends thereof. In the alternative, pliant layer 80 may be adhered to the outer surface of core 72 by means of suitable adhesives. In addition to mounting layer 78 to core 72, pliant layer 80 provides a wear resistant surface for prolonging the useful life of layer 78.
Compliant layer 78 is fabricated from any one a number of compressible materials. In the preferred embodiment, layer 78 is fabricated from urethane material having a Shore A durometer hardness in the range from around 50-60. Other materials having a similar hardness characteristic, such as closed cell foam materials, may be employed depending on the requirements of a particular application. To facilitate mounting of the layer 78, the outer surface of annular core 72 is provided with a recess as illustrated in the Figs. Mounting arrangements with different contours are contemplated and are within the scope of the invention.
In use, with wheel 70 mounted in the manner illustrated in FIG. 7, the compliant outer surface is brought into contact with the substrate in the manner depicted by manipulating arm 32. The compliant surface presses downwardly on the top surface of the substrate 18 and provides the force required to break the substrate 18 along the scribe line. The downward force is distributed across the scribe line and over the area of contact between the surface of the wheel 70 and the substrate 18. The maximum tensile strain induced across the scribe line is adjusted by changing the angle of the break plane surface 58 of mandrel 48.
In all embodiments of the break wheel, nut 38 can be quickly moved on and off end 40 of shaft 34. This permits quick replacement of a break wheel with another break wheel to accommodate a particular type of wafer.
While the above provides a full and complete disclosure of the preferred embodiments of the invention, various modifications, alternate constructions and equivalents may be employed as desired. For example, while specific materials have been identified above with reference to the preferred embodiments of the invention described above, other equivalent materials may be employed, as desired. For example, a single layer of compliant material having the desired hardness and a wear resistant outer surface may be substituted for the foam layer 78 and pliant layer 80 in the embodiment of FIGS. 7 and 8. Therefore, the above description and illustrations should not be construed as limiting the invention, which is defined by the appended claims.
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A method for applying a controlled, adjustable strain and strain rate by use of a break wheel to break a frangible semiconductor wafer around previously placed scribe lines formed along a surface of the wafer. Several embodiments of a break wheel are disclosed. One embodiment uses a pair of spaced profiles engageable on opposite sides of a scribe line on the wafer. Another embodiment uses three laterally spaced contact profiles, the center profile having a smaller radius than that of the two flanking contact profiles. Another embodiment uses a complaint break wheel for applying a resilient breaking force to the wafer in a region straddling the scribe line. All embodiments are used with a tilted surface having a break edge with which the scribe line is aligned prior to the application of the breaking force. The tilted surface is adjustable to provide a variable maximum strain limit.
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BACKGROUND OF THE INVENTION
A. Field of the Invention
The invention relates to the field of reducing turbulence in a fluid.
B. Related Art
In the field of energy dispersive x-ray analysis, vessels known as Dewars or cryostats are commonly used to cool the x-ray detectors to cryogenic temperatures. The cryostats are commonly filled with liquid nitrogen, but can be filled with any cryogenic liquid. Due to imperfections in the insulation of the cryostats, the cryogenic liquid may boil violently. The boiling results turbulence, which leads to vibration, which in turn can cause deterioration in the resolution of the x-ray detector.
Even when the boiling is of the nucleate type, from “hot” walls of the vessel, significant turbulence may occur. “Hot” in this context is of course relative to the temperature of the cryogenic liquid.
SUMMARY OF THE INVENTION
The object of the invention is to reduce turbulence in a fluid.
The object is achieved by using a porous material in the fluid.
The invention can also be used to distribute heat transfer throughout a fluid or reduce mass transfer throughout a fluid.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be described by way of non-limitative example with reference to the following drawings.
FIG. 1 shows a prior art cryostat.
FIG. 2 shows a cryostat with hard porous material
FIG. 3 Shows a cryostat with soft porous material
FIG. 4 shows an energy dispersive x-ray analysis unit cooled with a cryostat in accordance with FIG. 2 or FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a prior art cryostat. The cryostat may have any shape. The cryostat commonly has a vacuum vessel 101 , insulation 102 , and an inner vessel 103 . There is an opening at the top called a neck 104 for filling the vessel 103 with cryogenic liquid. The cryostat is closed by a non-hermetic cap 105 , which allows for continuous venting of the inner vessel.
FIG. 2 shows implementation of the invention in a cryostat. The vessel 103 is filled with a hard, porous material 206 . The material is porous in the sense that it is filled with passages for the cryogenic liquid to flow through. The majority of passages must communicate with each other throughout the vessel 103 so that the fluid can access them. The passages restrict the natural circulation of the cryogenic liquid into narrow channels, changing turbulent flow to laminar or transition flow.
The material preferably occupies 20-30% of the volume of the vessel 103 , with the rest of the space occupied by passages defined by the material. Conceivably the material might occupy as much as 50% of the volume of the vessel 103 . The hard porous material might be of a foamed and/or sintered type. Some appropriate materials could be metals, silica compounds, ceramics or polymers, e.g. aluminum, stainless steel, or quartz. An example of a suitable foamed material would be Duocel® metal/ceramic foam available from ERG Materials & Aerospace, 900 Stanford Ave, Oakland, Calif. 94608.
Since the passages should communicate, they might be embodied in just one passage with some turns, angles and/or forks or a spiral with one long, continuous curve. The term “a plurality of passages” as used herein therefore includes the situation of one passage with such a curve, turns, angles, and/or forks.
The material 206 is preferably secured to all walls of the vessel 103 at the time the vessel is built.
FIG. 3 shows an alternative embodiment of the invention. In this embodiment, a soft, porous material 306 is inserted in the vessel 103 . The soft, porous material is preferably fibrous such as metal wool or silica wool. Suitable metal wools are GSS-90 Stainless Steel Fibers or GCU-340 copper fibers, both available from Global Material Technologies, Inc., 1540 E. Dundeet Road, Suite 210, Palatine, Ill. 60067, tel. 1-847-202-7000. The metal wool can be added after manufacturing of the cryostat, by simple insertion through the neck 104 . After insertion, the metal wool expands to fill the vessel 103 . The soft, porous material 306 is preferably not secured to the walls of the vessel 103 .
Those of ordinary skill in the art will be able to devise other materials in line with the inventive concept explained herein to accomplish the function of reducing turbulence in the fluid. Also, the invention can be applied to vessels of other shapes and functions.
FIG. 4 shows an energy dispersive x-ray analysis unit provided with the cryostat 405 of FIG. 2 or FIG. 3 . The unit also includes an x-ray detector 402 cooled by the cryostat 405 , cold finger 401 , and processing apparatus 403 . The x-ray detector may be a lithium-drifted silicon crystal. The cold finger 401 is intended to provide good thermal contact between the detector 402 and cryostat 405 . The cold finger may also have means to attenuate vibrations.
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A porous material inserted into a fluid-containing vessel reduces turbulence, heat transfer, and mass transfer in the fluid. The material may be used in a cryostat to reduce turbulence in a boiling cryogenic fluid. The cryostat may be used in an energy dispersive x-ray analysis unit to cool an x-ray detector.
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This application is a continuation of application Ser. No. 460,021, filed Jan. 21, 1983, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to an internal combustion engine having an auxiliary intake or exhaust valve (or valves) in addition to main intake and exhaust valves for each cylinder, more particularly to an apparatus for actuating the valves.
2. Description of the Prior Art
Recently, multi-intake valve or multi-exhaust valve systems have been adopted in internal combustion engines for the purpose of increasing the engine output and decreasing the fuel consumption. In these systems, one (or two) auxiliary intake or exhaust valve is provided in addition to a pair of main intake and exhaust valves for each cylinder. A known means for actuating those valves is a twin cam shaft drive, wherein an auxiliary cam shaft is provided for the auxiliary value in addition to a cam shaft for the conventional main intake and exhaust valves. The provision of a twin cam shaft drive, however, not only means an increased number of cam shafts but also a more complex large and expensive drive. This is particularly serious in the case of an engine having a wedge-type combustion chamber, since there is not enough room to arrange the second cam shaft (auxiliary cam shaft). An improved drive mechanism of the valves has therefore been needed.
Alternatively, it has been known to actuate the valves by a single cam shaft. Such a known single cam shaft drive, however, needs two rocker arm shafts. Therefore, it also has the drawbacks of complexity, large size, and expensiveness of the valve drive, similar to the twin-cam shaft drive system.
SUMMARY OF THE INVENTION
The primary object of the present invention is, therefore, to eliminate the above-mentioned drawbacks by providing an apparatus, for actuating or driving a plurality of valves in an internal combustion engine, comprising a single cam shaft and no rocker arm shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be discussed below in detail with reference to the drawings showing preferred embodiments of the present invention; in which
FIG. 1 is a plan view of an apparatus for actuating intake and exhaust valves according to the present invention;
FIG. 2 is a sectional view taken along the line II--II in FIG. 1;
FIG. 3 is a partial view of a free end of the rocker arm viewed from the direction III in FIG. 2;
FIG. 4 is a perspective view of a keep spring shown in FIGS. 1 and 2;
FIG. 5 is a front elevational view of FIG. 4;
FIG. 6 shows a variant of a keep spring according to the present invention;
FIG. 7 is a view from an arrow VII in FIG. 6;
FIG. 8 is a view from an arrow VIII in FIG. 6;
FIG. 9 is a view similar to FIG. 1 but showing an arrangement in which keep springs shown in FIGS. 6 to 8 are used; and
FIG. 10 is a partial view similar to FIG. 2 but showing an arrangement in which keep springs shown in FIGS. 6 to 8 are used.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A main intake valve 1, auxiliary intake valve (third valve) 5, and main exhaust valve 3 are alternatively disposed on opposite sides of a cam shaft 17, i.e. a zigzag fashion viewed in a plane view, as shown in FIG. 1. These valves 1, 3, and 5 are located in main intake port 21, main exhaust port 23, and auxiliary intake port 25, respectively, as shown in FIG. 2, to open and close the associated ports. These ports 21, 23, and 25 open into a combustion chamber 20 defined in a cylinder 10 and are connected to a main intake passage 31, a main exhaust passage 33, and an auxiliary intake passage 35, respectively. The combustion chamber 20 may be of any shape, for example, a wedge shape or semishperical shape. Valve stems 1a, 3a, and 5a of the valves 1, 3 and 5 are slidably supported by respective stem guides 41, 45, etc., (stem guide for auxiliary valve 5 not shown) secured to a cylinder head 30. The valves 1, 3, and 5 are continuously biased toward their valve closed positions by respective return springs 51, 55, etc. (spring for auxiliary valve 5 not shown). The above-mentioned arrangement is a typical construction for an internal combustion engine having three valves.
According to the present invention, cams 61, 63, and 65 for actuating the respective valves 1, 3 and 5 are secured to a common single cam shaft 17. The cams 61, 63, and 65 have cam profiles based upon predetermined valve timings of the respective valves 1, 3, and 5. According to the present invention, between the cams 61, 63, and 65 and the top ends of the valve stems of the associated valves 1, 3, and 5 are provided swing-type rocker arms 71, 73, and 75 adapted to transmit the movement of the cams to the respective valves. The rocker arms 71, 73, and 75 have bifurcated free ends 73a, 75a, (free end of valve stem 1a of main intake valve 1 not shown) in which the top ends of the associated valve stems are held so as not to come out of the bifurcated free ends, as shown in FIG. 3. The top ends of the valve stems 1a, 3a, 5a, are pushed down by the respective rocker arms 71, 73, and 75 against the respective return springs 51, 55, etc. to open the respective valve ports 21, 23 and 25. The rocker arms 71, 73, and 75 have pivots at their other ends for swing movement. That is, the rocker arms have, at the other ends opposite to the free ends, threaded holes (only threaded hole 83 of rocker arm 73 shown in FIG. 2), in which adjusting screws 91, 93, and 95 are screwed. The adjusting screws are secured to the respective rocker arms by means of locknuts 101, 103, and 105, so that the relative positions of the adjusting screws and the associated rocker arms can be adjusted to adjust tappet clearances of the rocker arms.
The adjusting screws 91, 93, and 95 have generally semispherical lower ends (fulcrum for swing movement) 123, 125, lower end of adjusting screw 95 etc. (not shown) fitted in corresponding generally semispherical recesses 133, and 135 (only two recesses shown) provided in fulcrum bearing portions 143, 145 (only two bearing portions shown) integral with the cylinder head 30, for the independent swing movement of the rocker arms, respectively. The adjusting screws and, accordingly, the rocker arms tend to cause a universal motion or bound motion, because of the semispherical fulcrum (universal joint pivots). In order to prevent such a universal or bound motion, keep springs 151, 153, and 155, as shown in FIGS. 4 and 5 are attached to the rocker arms 71, 73, and 75, respectively.
Each of the keep springs has opposed coiled portions 154 and a straight abutment portion 156 which bears against the upper surface of the associated rocker arm 71 (73, 75) to push the rocker arm downward. The opposite ends of one keep spring 151 (153, 155) come together and are bent downward to form projections 158. The keep springs are of a symmetrical shape with respect to the projections 158. The end portions adjacent to projections 158 of each of the keep springs are fitted and held in corresponding peripheral grooves 164 formed in the bearing portions 143, 145, etc., and projections 158 are inserted into recesses 163, 165, etc. which are connected to the peripheral grooves (see partial cross section of bearing portion 145 in FIG. 2). The projections 158 can be welded to each other to prevent them from coming apart from each other. The rocker arms are thus continuously biased toward valve open positions of the associated valves by the keep springs. However, the spring force of the keep springs is smaller than that of the valve springs 51, 53, etc. and, accordingly, the keep springs are not strong enough to open the valves 1, 3, etc. against the valve springs which urge the associated valves into the valve closed position. Alternatively, the projections 158 can be dispensed with. Namely, it is not always necessary to bend the opposite ends of the springs downward.
According to the present invention, the fulcrums 123, 125, etc. of the rocker arms 73, 75, etc. are located on the opposite sides of an axis X--X of the cam shaft 17 in an alternate arrangement, i.e., in a zigzag fashion. The rocker arms 71, 73, and 75 are properly shaped so that they not only do not interfere with each other, but also do not interfere with the valve springs and the keep springs.
The valves 1, 3, and 5 are actuated by the respective cams 61, 63, and 65 secured to the common cam shaft 17, in accordance with predetermined valve timings depending on the cam profiles of the cams. The movements of the cams are transmitted to the associated valves by means of the swing-type rocker arms in an alternate arrangement.
FIGS. 6 to 8 show a variant of the keep spring 151 (153, 155) shown in FIGS. 4 and 5. The keep spring which is composed of a coiled spring in FIGS. 4 and 5 is replaced by a bent leaf spring 251 (253, 255) in FIGS. 6 to 8. The leaf spring 251 (253, 255) has an opening 252 through which the associated adjusting screws 91, 93, etc. extend. The leaf spring 251 (253, 255) has a bent end 254 which can be attached to the associated rocker arm 71 (73, 75) so as to bias the rocker arm downward. The other end 256 of the leaf spring is connected to the associated fulcrum bearing portion 141 (143, 145).
FIGS. 9 and 10 show arrangements similar to FIGS. 1 and 2, respectively, in case of the use of leaf springs shown in FIGS. 6 to 8. It should be appreciated that the leaf spring can be easily manufactured and can have a larger spring force in comparison with the coiled spring as shown in FIGS. 4 and 5. The illustration of FIG. 9 is more practical in comparison with FIG. 1, but the operation of the modified arrangement shown in FIGS. 9 and 10 is quite the same as that of FIG. 1. Therefore, no detailed explanation for FIGS. 9 and 10 is given.
As can be understood from the above description, according to the present invention, since the intake and exhaust valves are actuated by the rocker arms which swing about the respective fulcrums located in an alternate arrangement and which are, in turn, actuated by a single common cam shaft, rocker arm shafts which would be otherwise necessary as in the prior art can be dispensed with, thus resulting in a simplified and inexpensive construction.
Finally, it should be noted that the number of the valves is not limited to three, that is, the number of the auxiliary valve is not limited to one. For example, an internal combustion engine having four valves, including one auxiliary intake valve and one auxiliary exhaust valve in addition to main intake and exhaust valves, for each cylinder is well known. The invention is, of course, applicable to such an internal combustion engine having four valves for each cylinder, wherein the four valves can be actuated by four swingable rocker arms arranged in a zigzag fashion in a way similar to the above mentioned embodiments directed to three valves.
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An apparatus for actuating valves consisting of a pair of main intake and exhaust valves and at least one auxiliary intake and/or exhaust valve, comprising cams on a single common cam shaft, for driving the associated valves, and rocker arms which can independently swing about fulcrum located in an alternate arrangement in an axial direction of the cam shaft, to transmit the movements of the cams to the associated valves so as to independently drive the valves.
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This invention was made with Government support under DAAK60-87-C-0016 awarded by U.S. Army Natick Research, Development and Engineering Center. The Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
This invention relates to burners which utilize a pressurized supply of fuel and which vaporize the fuel prior to combustion.
Liquid-fueled burners that do not require any external source of power are in common use as portable heat sources for applications such as campstoves and military field kitchens. Generally such burners store the fuel in a pressurized fuel tank and vaporize the liquid fuel prior to combustion in order to provide for complete mixing with combustion air and in order to provide a pressurized gas stream to propel the mixture to the burner head. In the past, most such burners utilized highly volatile fuels such as gasoline or kerosine, since these fuels vaporize at a low temperature, making it easy to heat the vaporizer and maintain the fuel in the vapor state. Operation with less volatile fuels, such as diesel fuel, is far more difficult, since diesel fuel vaporizes at a relatively high temperature, on the order of 600-700 degrees Fahrenheit, making it far more difficult to heat the vaporizer and to deliver the fuel to the burner as a vapor. Moreover, at elevated temperatures liquid fuels tend to decompose, resulting in the formation of carbon and tars which foul the vapor passages. Nonetheless, it is highly desirable to use diesel fuel, since it is much safer than gasoline and is readily available in the military, which uses it as a universal automotive fuel.
Prior-art burners exist that are capable of burning liquid fuels without an external source of power. The vaporized fuel is generally accelerated under pressure in a nozzle, and the resulting fuel vapor jet entrains some or all of the air required for combustion. A common example of this class of burners is the "Coleman Stove", which utilizes a closed fuel tank which is pressurized by pumping air into the fuel tank. The fuel is forced out of the tank by action of the tank pressure and flows through a "generator" in which the fuel is vaporized. The heat necessary for vaporization is provided by a "pre-heat burner" during start-up, and following the pre-heat period, by heat from the main burner. The generator may take many forms, but commonly takes the form of a tube heated on the outside by a preheat burner, and once the main burner is ignited, by the main burner flame. From the generator, the now-vaporized fuel flows through a nozzle in which it accelerates to a high velocity, and then mixes with and entrains air for combustion. The air/fuel mixture then flows to a burner head, which anchors the flame. A fuel valve is generally provided to modulate and/or shut-off the flow of fuel. The fuel valve may control either the liquid fuel or the vaporized fuel.
Other examples of prior-art, non-powered, vaporizing, liquid-fueled burners include:
MSR X/GK campstove (gasoline, kerosine or diesel fuel)
Optimus 199 Ranger (alcohol, gasoline, kerosine)
Coleman Peak 1 (gasoline or kerosine)
Optimus III Hiker (gasoline or kerosine)
U.S. Army M-2 Gasoline Burner Unit (gasoline)
Haas+Sohn V75/1 Type Multicombustible Burner (gasoline, kerosine, diesel fuel)
Karcher Field Kitchen Burner (Gasoline, kerosine, diesel fuel)
The first four prior-art citations are examples of small campstoves, typically under 10,000 BTU/hr output, that may be carried in a back-pack for individual use. The latter three citations are examples of field-kitchen burners having capacities on the order of 60,000 BTU/hr. It is somewhat easier to burn low-volatility fuels in the smaller burners since the entire burner and fuel delivery system may be heated by conduction from the burner head. On account of their larger size, it is more difficult to conduct sufficient heat throughout the larger burners to prevent fuel vapor from condensing in the passages leading from the vaporizer to the burner. The present invention is directed towards solving this problem in larger burners.
Prior-art burners suffer from a number of additional deficiencies which the present invention is intended to overcome. These include:
Slow Start-Up--Many burners, particularly those of larger capacity, are slow-to-start because of the large mass of their vaporizers.
Large Size and Weight--Some burners are heavy and bulky, which is a disadvantage in a burner intended for field use.
Complex and Expensive--Some burners use complex and expensive mechanisms.
Unsafe Operation--Some burners may allow unsafe operation by overheating the fuel tank or burner parts, allowing fuel to drip from the burner, or storing a large volume of vaporized, pressurized fuel.
Unstable Operation--Some burners may operate in a pulsating mode or may be subject to flooding during start-up.
High Maintenance--Most vaporizing burners are subject to fouling of the vapor passages by tars formed by the fuel. This problem is particularly acute in small vapor passages.
Noisy, Dirty Combustion--Many burners produce smoky flames as a result of insufficient combustion air or poor mixing with air or require high air pressure to provide sufficient combustion air, which results in a noisy burner.
DISCLOSURE OF THE INVENTION
In accordance with the present invention, liquid fuel is vaporized and then burned on a flame holder of a burner. A vapor generator comprises at least one vertical tube having fins exposed to a flame on the flame holder. Liquid is vaporized within the vertical tube. A vapor flow control valve is positioned between the vapor generator and the flameholder. Preferably, a liquid flow restrictor is provided between a liquid fuel tank and the vapor generator.
Preferably, the flame holder is a cylindrical screen mounted on a vertically oriented fuel and air mixer over a fuel nozzle. A cup is formed about the nozzle to collect any condensed fuel from the mixer. The mixer is preferably of high thermal conductivity material and is heated by the flame to minimize condensation. A flame deflector surrounds the flame holder and directs the flame upward. The deflector also serves to collect any fuel which condenses at the flame holder during start-up.
A superheater tube carries fuel vapor from the vapor generator past the flame to the fuel nozzle. Preferably, the superheater connects into a strainer and is easily disconnected for cleaning.
By means of the present invention, a burner is capable of burning less volatile liquid fuels without any external source of power. The burner can ignite rapidly from a cold initial state and is ready to operate in a short time. It is compact, lightweight, simple and of inexpensive construction. It is safe and operates in a stable manner under all conditions. Further, it requires little maintenance and operates cleanly and quietly with a low pressure fuel supply.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a vaporizing burner embodying the present invention.
FIG. 2 is a more detailed schematic illustration of the mixer/aspirator of the burner of FIG. 1.
FIG. 3 is a detailed cross-sectional schematic view of the vapor generator of the burner of FIG. 1.
FIG. 4 is a side view of the vapor generator of FIG. 1.
FIG. 5 is a longitudinal-sectional view of a safety valve in the burner of FIG. 1.
FIG. 6a and 6b are cross-sectional and longitudinal-sectional views of the flame control valve of the burner of FIG. 1.
FIG. 7 is a side view of the mixer, flame holder and vapor generator of the system of FIG. 1.
DESCRIPTION OF THE INVENTION
The principal features of the invention are described in the following figures.
FIG. 1 shows a schematic of the burner system. Fuel storage tank 10 contains dip-tube 12 which draws fuel from the bottom of the tank into preheat torch 18 through conduit 14 and shut-off valve 16. Compressed air is drawn from the top space 20 of fuel tank 10 through conduit 22 to mix with the liquid fuel in torch 18. The flame 24 of the preheat torch 18 heats vapor generator 40 to start the main burner 100. Once the vapor generator 40 has been heated to a sufficient temperature, on the order of 700 degrees Fahrenheit, fuel safety valve 200 is opened, admitting liquid fuel to vapor generator 40. Liquid fuel flows from tank 10 through dip tube 30, through conduit 32 and fuel metering orifice 34 to the fuel safety valve 200. Fuel metering orifice 34 limits the rate of fuel flow so that vapor generator 40 will not become flooded with unvaporized fuel. By thus limiting the rate of liquid flow, fuel can be vaporized at a sufficient rate within vaporizer 40 to build a back-pressure which prevents excessive in-flow.
After the fuel safety valve 200 has been opened, vapor flow control valve 300 is opened. This permits fuel vapor to flow from vapor generator 40 through superheater 60 and conduit 70, through vapor flow control valve 300, and into fuel vapor nozzle 320. The vapor issues from vapor nozzle 320 as a high-velocity jet, entraining primary air into mixer/aspirator 340, which delivers the fuel/air mixture to burner head 100. Once ignited by the preheat burner flame 24, the burner flame 110 heats the vapor generator 40 and superheater 60, which in turn heats the fuel vapor flowing within it to a temperature on the order of 1000 degrees Fahrenheit. This superheating compensates for heat loss by the fuel vapor as it flows through conduit 70, vapor valve 300, and nozzle 320.
In one embodiment, fuel safety valve 200 may be a normally-closed electric solenoid valve powered by a thermocouple 250. To admit fuel to the vapor generator 40, valve 200 is manually kept open until flame 110 or 24 heats thermocouple 250 sufficiently to generate enough power to hold valve 200 in the open position. In the event of a loss of flame for any reason, thermocouple 250 would cool and allow valve 200 to close, thereby shutting-off the fuel flow. This arrangement also permits thermal fuses or thermostatic switches to be placed in series with the thermocouple leads 252 to open the circuit if an unsafe temperature is reached.
FIG. 2 shows the arrangement of burner 100 and mixer/aspirator 340. Burner head 100 comprises burner screen 110 fitted between top cap 114 and bottom cap 116, and flame deflector 120. Burner screen 110 comprises a cylinder of heat resistant sheet-metal such as stainless steel that is perforated with numerous holes or slots, each having a minor dimension of not more than 0.03 inches and representing an open area of 10% to 20% of the total surface area of the cylinder. Top cap 114 is preferably made of a thin heat-resistant sheet-metal such as stainless steel, and may optionally contain additional burner ports. Bottom cap 116 is preferably constructed of a highly conductive metal such as copper which has been plated with nickel to minimize oxidation. Bottom cap 116 is bonded to mixer tube 346, which preferably is similarly constructed of nickel-plated copper. In the preferred embodiment, heat from the burner flame is conducted by bottom cap 116 and mixer tube 346 down to the inlet 356 of the mixer/aspirator 340. Flame deflector 120 serves to impose a vertically upward component to the primarily radial flow direction of the flame leaving burner screen 110. It also serves to collect any condensation of fuel during startup for subsequent evaporation and burning. Preferably deflector 120 is constructed of heat-resistant sheet-metal such as stainless steel.
Mixer/aspirator 340 comprises mixer tube 346 connected to mixer inlet 356 and fuel vapor nozzle 320. Mixer inlet 356 has an open bellmouth end connected to mixer tube 346 and an opposite flat base 366. The sides of inlet 356 contain openings 370 which admit combustion air to the mixer/aspirator 340. Preferably, openings 370 may be adjusted by a sliding or rotary shutter (not shown). Fuel nozzle 320 is fitted and bonded to a hole centered in base 366 to direct the fuel vapor jet 330 along the centerline of mixer tube 346. The vapor jet 330 entrains and induces combustion air to flow into the mixer inlet openings 370 and along mixer tube 346 into burner 100.
Since mixer/aspirator 340 is heated by conduction from burner 100, once the burner has reached a steady operating temperature fuel does not condense within the mixer/aspirator. During startup, any fuel that does condense within the burner 100 or mixer aspirator 340 is collected within the base 366 of inlet 356. During subsequent operation, that liquid evaporates.
FIG. 3 shows the form of vapor generator 40. Vapor generator 40 is placed between burner head 100 and preheat torch 18 in order that it may be heated by the flame of either. Liquid fuel enters from conduit 36 through inlet manifold 42 which is connected to one or more riser tubes 44. Riser tubes 44 have fins 46 at the top which are positioned to be heated by the flames from both the preheat torch 18 and main burner 100. Vaporized fuel exits from the top(s) of riser tube(s) 44 into outlet manifold 48, from which the fuel vapor then flows into superheater 60 (not shown).
Most of the heating of the fuel occurs within the finned section 46 of riser tube(s) 44. A liquid-vapor interface 50 will normally exist within the finned section 46. Below the liquid-vapor interface 50 liquid fuel is heated to its saturation temperature and caused to vaporize and bubble. Above the interface 50 the fuel is mostly in the vapor state, and as a result of the significantly lower coefficient of heat transfer to the vapor in comparison to the liquid, relatively little heating of the fuel occurs above interface 50.
The elevation of interface 50 within riser 44 is established by a balance between the rate of vaporization and the flow of vapor out of nozzle 320 (not shown, see FIG. 1). If interface 50 is below its equilibrium elevation, less of the interior surface of riser 44 is exposed to liquid, resulting in lower heat input and a correspondingly lower rate of evaporation of fuel. This in turn causes a lower rate of flow through nozzle 320 and vapor valve 300, which results in a lower back-pressure. If the back-pressure is less than the supply pressure established by the pressure in fuel tank 10 (not shown), less any pressure drop caused by flow resistance and elevation change, the flow of liquid fuel into riser 44 will increase, causing interface 50 to rise. This in-turn will increase the surface of liquid being heated, thus increasing the evaporation rate and reestablishing equilibrium.
The rate at which interface 50 will rise or fall in response to a perturbation from equilibrium is governed in part by the resistance of orifice 34 (See FIG. 1). It has been found that a flow resistance sufficient to limit fuel flow to between twice to six times the normal rate of evaporation in the vapor generator 40 will prevent flooding or flow oscillation while permitting good modulation of the burner. Moreover, by limiting the maximum diameter of orifice 34 to 0.020 inches, it acts as a flame arrestor, preventing a flashback of flame from entering the fuel tank.
The use of the vertical vapor generator in combination with the flow-limiting liquid orifice eliminates the problems of flooding and flow oscillations common with other non-powered burners, resulting in a safer, easier-to-operate burner.
Some prior-art generators have sought to solve the problem of flow oscillation by using a small diameter/volume vapor generator (e.g., 1/4 inch internal diameter), which causes the frequency of flow oscillation to increase to a point at which the oscillation may not be objectionable. However, such vapor generators are highly susceptible to fouling by the tars which remain after the lighter fuel fractions have evaporated. Riser(s) 44 preferably have an internal diameter between one-half inch to one inch. Diameters smaller than one-half inch may result in premature failure due to the build-up of tar or carbon, which may block the flow within the vapor generator. Larger diameters result in a larger thermal mass, requiring longer time to preheat the vapor generator.
FIG. 4 shows a preferred embodiment of vapor generator 40. Liquid fuel supply tube 36 is joined to inlet manifold tee 442 by soldering, brazing, welding or similar bonding method. Inlet tubes 410 and 412 are also bonded to manifold 442 and extend into riser tubes 444 through compression fittings 420 and 430. Compression fittings 420 are fitted to inlet tubes 410 and 412 and are joined to compression fittings 430, which are fitted to riser tubes 444. Riser tubes 444 are joined to finned tubes 450 having fins 446 by a suitable high-temperature method of bonding, such as "nicro-brazing" or welding. Fins 446 may be machined in tubes 450 or may be stamped out of sheet-metal and brazed to tubes 450. Outlet header 448 may be made out of a closed rectangular tube that is brazed to the top of finned tubes 450 and brazed or welded to the inlet 460 of superheater 60.
This preferred embodiment provides an economical construction which facilitates cleaning of the interior of the vapor generator by unscrewing the compression fittings 420 and 430. Tubing 36, 410 and 412, and fittings 442 and 420 may be constructed of inexpensive low-temperature materials, such as copper or brass, since they are not exposed to high temperature. The remainder of the assembly should be constructed of temperature-resistant materials, such as stainless steel.
FIG. 5 shows a cross-sectional view of fuel safety valve 200. Fuel enters through inlet fitting 210 to inlet plenum 220 within housing 230. Valve plug 240 is fitted to shaft 242 which is surrounded by solenoid winding 244. Spring 246 positioned between solenoid winding 244 and plug 240 forces "O" ring 248 contained in plug 240 against valve seat 232 when the solenoid is deenergized, sealing inlet plenum 230 outlet plenum 260 and outlet fitting 262. Valve plunger 270 is used to manually open valve 200 by pushing on push-button against return spring 274. Plunger "O" ring 276 prevents leakage of fuel between plunger 270 and housing 230. Thermocouple 250 is connected through thermocouple lead 252 and connector 254 and feedthrough 256 to solenoid winding 244. Optional series connector 258 has external terminals 259 which provide connection to an external series loop which may contain thermostatically activated fuses or switches to interrupt the circuit between thermocouple 250 and solenoid winding 244.
In operation, after vapor generator 40 has been heated sufficiently by preheat torch 18, push-button 272 is depressed and held in the depressed position, pushing valve plug 240 away from seat 232 until thermocouple 250 is heated sufficiently by the main burner so that solenoid 244 captures shaft 242 and button 272 may be released. In the event of a flameout, thermocouple 250 will cool, thereby reducing its electrical output, deenergizing solenoid 244 and allowing spring 246 to close plug 240. If any optional thermal switches or fuses are used in combination with optional connector 258, any event which causes them to open will also result in closing of the safety valve.
FIGS. 6A and 6B show one form of a combination vapor flow control valve 300 and fuel vapor nozzle 320. Vaporized fuel enters from superheater outlet conduit 70 through valve inlet 310. Valve stem 350 has male threads 352 which engage female threads 302 in valve body 300 to enable valve tip 340 to seal against valve seat 330 in body 300. Valve stem 350 is sealed in body 300 by packing 354 and packing nut 356. Outlet plenum 370 comunicates with chamber 372 into which is screwed vapor nozzle 320, sealed with nozzle gasket 322. Pinion gear 360 is located on valve stem 350 between threads 352 and valve tip 340. Gear 360 engages rack 362 which contains cleanout pin 364. When valve stem 350 is rotated to draw valve tip 340 away from seat 330, gear 360 causes rack 362 to rise. Further opening of the valve causes the cleanout pin 364 in rack 362 to pass through the orifice in vapor nozzle 320, thereby clearing away any debris that may have collected at the orifice.
In a preferred embodiment, cleanout pin 364 may be a twist drill shortened to an appropriate length. The flutes in the twist drill permit vapor to flow through the orifice while the nozzle is being cleaned, thereby permitting the nozzle to be cleaned without extinguishing the main burner.
Additionally, the cleanout pin 364 may be used as a modulating valve, using the nozzle 320 as a secondary valve seat. This can be advantageous when operating the burner at its minimum firing rate, since this causes the nozzle to operate as a variable-area nozzle, maintaining a high vapor velocity through a reduced nozzle cross-sectional area. This results in greater entrainment of air at a given vapor flow rate than if the vapor were throttled by the main vapor flow control valve at seat 330.
FIG. 7 shows an assembly of the vapor generator, vapor flow control valve and burner/mixer. Vapor generator 40 is attached by clamp 140 to bracket 130 which is bonded to deflector 120 of burner head 100. Fins 46 are positioned to be opposite burner screen 110, and tubular superheater 60 is connected to outlet header 48 and coils about burner screen 110 for approximately 180 degrees before bending downward to the vapor flow control valve 300. The body of valve 300 is fitted and bonded to a hole in the base 366 of mixer inlet 356, securely aligning the nozzle 320 with the centerline of mixer tube 346.
In a preferred embodiment, vapor strainer 72 is positioned between superheater 60 and valve 300 to trap any carbon particles that may have been formed in the vapor generator or superheater and which may clog the vapor valve or vapor nozzle. Superheater tube 60 is readily disconnected from strainer 72 for ease of cleaning. Mixer inlet 356 may also be separably attached to mixer tube 346 and fastened by hose clamp 380. Cable 376 attached to tab 374 on rotary shutter 372 may be used to adjust the position of shutter 372 over air slots 370 to alter the ratio of air to fuel.
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Diesel fuel is vaporized and then burned on a cylindrical screen flame holder. The fuel is vaporized in a finned, vertical tube vapor generator and directed through a superheater tube past the flame to a flow control valve and nozzle. A flow restriction is provided between a liquid fuel supply and the vapor generator. The flame holder is vertically supported over a mixer and the nozzle. A flame deflector about the flame holder and a reservoir about the nozzle collect fuel condensate during start-up.
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CROSS REFERENCE TO RELATED PATENT
This application is related to the commonly assigned U.S. Pat. No. 4,327,590, granted May 4, 1982; and entitled "METHOD AND APPARATUS FOR DETERMINING SHIFTS AT TERRAIN AND IN STRUCTURES".
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved method of measuring fluid pressure i.e. liquid or gas pressure in a sealed bore hole. The present invention also relates to a new and improved construction of a measuring tube for measuring such pressure as well as to a new and improved construction of a measuring probe for such measuring tube.
In its more particular aspects, the present invention specifically relates to a new and improved method for measuring fluid pressure in a sealed bore hole by means of a measuring tube inserted into the bore hole. In given areas or regions of the bore hole where the pressure measurement is to take place and on both sides of each area or region in which the respective measurement is planned, the bore hole is sealed by sealing means which are provided between the bore hole wall and the outer wall of the measuring tube. The measurement takes place by means of a measuring probe whose component, which is designed for such measurement, is placed or arrives at a measuring location provided in the wall of the measuring tube.
A method of this type is known from U.S. Pat. No. 4,192,181, granted Mar. 11, 1980, and U.S. Pat. No. 4,230,180, granted Oct. 28, 1980. The measurement of the pressure takes place, for example, for geophysical investigations, e.g. for tunnel construction, for investigations of the underground or subterranean regions at dams or other constructions or also for determining the lowering of the water table.
According to the prior art method, the measurement of the pressure occurs in that a valve provided in the wall of the measuring tube which is opened by the measuring probe, establishes a connection with an inner chamber of the measuring probe in which the measurement takes place. Because of the transition of the medium to be measured into the measuring probe, it is possible for changes of pressure to take place which lead to a faulty result. Furthermore, it is possible that solid particles can lead to malfunction of the valve mechanism used for this purpose.
SUMMARY OF THE INVENTION
Therefore with the foregoing in mind, it is a primary object of the present invention to provide a new and improved method of measuring fluid pressure in a sealed bore hole and which does not exhibit the aforementioned drawbacks and shortcomings of the prior art constructions.
A further important object of the present invention aims at providing a method of measuring fluid pressure which renders possible a high precision of measurement without having the medium to be measured entering into the measuring tube.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the method of the present development is manifested by the features that the measurement of the pressure is achieved by measuring the force necessary to move a pressure receiving component or sensing element by means of the measuring probe inserted into the measuring tube. The pressure receiving component or sensing element is movably and sealingly mounted in the wall of the measuring tube and is loaded by the pressure which is effective on the outside of the measurement tube.
As alluded to above, the present invention is not only concerned with the aforementioned method aspects but also relates to a new and improved measuring tube for carrying out such method. Such measuring tube is of the type containing externally mounted sealing means or devices for providing a sealing connection with the surrounding bore hole wall, and a measuring location located between at least two sealing means or devices serially arranged in lengthwise direction of the measuring tube.
More specifically, the inventive measuring tube contains a measuring cell which is sealingly inserted into an opening in the measuring tube wall at the measuring location. A housing of the measuring cell encases a pressure-receiving component or sensing element which is movably arranged in the housing and which is acted upon by the pressure of the medium surrounding the measuring tube. An inner space of the housing is sealed against the space which surrounds the measuring tube, by means of a seal which is movable conjointly with the pressure-receiving component or sensing element.
As further alluded to above, the present invention is not only concerned with the aforementioned measuring tube aspects but also relates to a new and improved measuring probe which is used in combination with such measuring tube and which is of the type containing guide wheels.
More specifically, the inventive measuring probe contains a measuring device or means provided with a contact element or measuring wheel which makes a measuring contact with the pressure-receiving component or sensing element of the measuring tube. The measuring means is provided with means for measuring the force required for moving the pressure-receiving component or sensing element against the pressure exerted by the medium surrounding the measuring tube and which pressure is to be measured.
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 throughout the various figures of the drawings there have been generally used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 is a schematic illustration of an axial section of a portion of a first exemplary embodiment of the inventive measuring tube for measuring fluid pressure and mounted in a bore hole;
FIG. 2 shows an axial sectional view of the measuring tube in accordance with FIG. 1, in the region of a measuring position;
FIG. 3 shows a cross-section through a measuring cell of the measuring tube in accordance with FIG. 1 and enlarged in relation to the illustration of FIGS. 1 and 2;
FIG. 4 shows a schematic side view of a measuring probe with a portion of the measuring tube in accordance with FIG. 1;
FIG. 5 shows a cross-section through the measuring probe in accordance with FIG. 4 in a travelling position relative to the measuring tube;
FIG. 6 shows a cross-section through the measuring probe in accordance with FIG. 4 in a measuring position relative to the measuring tube;
FIG. 7 shows an axial section through the middle or central portion of the measuring probe in accordance with FIG. 4;
FIG. 8 shows a cross-section along the line VIII--VIII of FIG. 7;
FIG. 9 shows a cross-section along the line IX--IX of FIG. 7;
FIG. 10 shows a cross-section along the line X--X of FIG. 7;
FIG. 11 shows an axial partial section of the rear end of the measuring probe in accordance with FIG. 4;
FIG. 12 shows an axial partial section through the front end of the measuring probe in accordance with FIG. 4;
FIG. 13 shows a schematic illustration of a portion of a second exemplary embodiment of the inventive measuring tube mounted in a bore hole and provided with a sealing device;
FIG. 14 shows a cross-section through a filling valve mechanism used in combination with the measuring tube shown in FIG. 13; and
FIG. 15 shows a cross-section through an exhaust or venting mechanism used in combination with the measuring tube shown in FIG. 13.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, it is to be understood that to simplify the showing thereof, only enough of the apparatus for measuring fluid pressure in a sealed bore hole has been illustrated therein as is needed to enable one skilled in the art to readily understand the underlying principles and concepts of the present invention. Turning now specifically to the drawings, a first exemplary embodiment of the inventive measuring tube 1 will be seen to comprise serially arranged individual tubular pieces 2 and connecting couplings or coupling sleeves 3 interconnecting the tubular pieces 2. This arrangement is such that by continuous joining of the tubular couplings or coupling sleeves 3 and the tubular pieces 2 and conjointly therewith further inserting the resulting measuring tube 1 into the bore hole 4, such measuring tube 1 can be assembled to achieve a desired length with a corresponding number of measuring locations 5 provided in the tubular couplings or coupling sleeves 3.
A sealing means or collar 6 is fastened to the outside of the tubular piece 2 in a not here further described manner. A not particularly illustrated filling conduit connects the sealing means or collars 6 of the tubular pieces 2 with each other. This filling conduit allows the sealing means or collars 6 to be placed under pressure by supplying a rheological fluid medium, for example, gas, water or cement mortar. Thus, the sealing means or collars 6 can be fixedly and therefore sealingly placed against the bore hole wall 7 of the bore hole 4. In this manner, each measuring location 5 is enclosed between two sealing means or collars 6 so that at the measuring location 5, the pressure existing in this enclosed area or region can be measured. This pressure can be formed by gas or liquid which has seeped or penetrated from the surrounding material 8 into the space 9 between the measuring tube 1 and the bore hole wall 7.
For the guidance of wheels or guide wheels 10 and 11 of a measuring probe 40 illustrated in FIGS. 4 to 12, the individual tubular pieces 2 and the tubular couplings or coupling sleeves 3 possess guide grooves 12 which extend axially parallel to the measuring tube 1 at angular distances of about 120° from each other. The tubular couplings or coupling sleeves 3 and the tubular pieces 2 have to be mounted in a predetermined angular position relative to each other to ensure that the guide grooves 12 of the tubular pieces 2 and the tubular couplings or coupling sleeves 3 can merge with each other. For this purpose, a form-locking engagement is provided between the tubular pieces 2 and the tubular couplings or coupling sleeves 3 as illustrated, for example, in FIG. 2 by extensions 13 and 14 which are formed in one of the two parts and engage correspondingly formed recesses 15 and 16 of the other part. It is to be understood that such a form-locking connection can be achieved in various ways as also can be the securing of the position of the components with respect to each other in axial direction by means of radially or tangentially extending screws or bolts which extend through both parts to be interconnected. However, the connection has to occur such that the measuring tube 1 is fluid tight. In accordance with FIG. 2, an O-ring 18 is placed in each circumferential groove of the tubular piece 2 such that the tubular coupling or coupling sleeve 3, which surrounds the tubular piece 2, sealingly engages with its inner wall the O-ring 18.
Furthermore, stop lugs 20 are provided on the inside of the tubular couplings or coupling sleeves 3 next to each guide groove 12. These stop lugs 20 serve for the exact positioning of the measuring probe 40 in its measuring position as will be further described hereinbelow.
A threaded hole 22 is provided at the measuring location 5 of the tubular coupling or coupling sleeve 3 and a threaded connector 23 of a housing 24 of the measuring cell 25 is threadably connected with the threaded hole 22. An O-ring 26 placed between the measuring cell housing 24 and the tubular coupling or coupling sleeve 3, ensures sealing of the measuring tube 1.
A piston 27 constructed as a pressure receiving component or sensing element is movably mounted in the measuring cell 25 and a plunger, i.e. a piston rod or stem 28 of the piston 27 is guided in an axial ball bearing 29 in the threaded connector 23 of the housing 24. The inner space of the housing 24 which accommodates the piston 27 is sealed towards the outside, i.e. against the space 9 in which prevails the pressure to be measured, by means of a thin, highly elastic seal or membrane 30. The outer end face of the piston 27 makes contact with this seal or membrane 30 or is fastened thereto, for instance, by adhesive bonding. The pressure acting upon the seal or membrane 30 is consequently transferred to the piston 27 such that the underside of the piston 27 comes to bear upon an inner shoulder 32 of the housing 24. Only a very short piston travel 33 is necessary for the measurement of the pressure.
The seal or membrane 30 is covered at a very small distance therefrom by a protecting or protective filter plate 35 which is inserted into a housing cover 36 which holds the seal or membrane 30 at the housing 24. The unit comprising the piston 27 and the seal or membrane 30 is pre-loaded or biased in the direction of the inner space of the measuring tube 1 by means of a compression spring 31 in order to permit the measurement of a lower pressure on the outside relative to the pressure existing inside the measuring tube 1, which normally is atmospheric pressure. The pressure acting upon the inside of the seal or membrane 30 is therefore compensated by this compression spring 31. According to the illustration in FIG. 3, the compression spring 31, for example, is clamped between the protective filter plate 35 and a cover plate 34 engaging the seal or membrane 30. For measuring higher pressures, the compression spring 31 can be dispensed with.
The free end of the piston rod or stem 28 projects by a small extent into the inner space of the tubular coupling or coupling sleeve 3 and possesses a rounded dome 38 which is intended for providing the mechanical measuring contact with the measuring probe 40 to be described in further detail in the following.
The measuring probe 40 is constructed as an elongate cylindrical body with a middle or central portion 41. The middle or central portion 41 is rotatable about a longitudinal axis of the measuring probe 40 relative to end portions 42 and 43 which are guided by the wheels or guide wheels 10 and 11. The mutual mounting of the middle or central portion 41 and the end portions 42 and 43 of the measuring probe 40 is achieved by means of pairs of slide bearings 45, 46 and 47, 48 (cf. FIGS. 11 and 12) which are provided at the related inner and outer ends of the end portions 42 and 43. The slide bearings 45, 46 and 47, 48 support related elongate axial shafts 50 and 51 which are formed at the associated outer ends of the middle or central portion 41 of the measuring probe 40. The axial shaft 51 which is enclosed by the front end portion 43 of the measuring probe 40, also serves as an operating rod for turning or rotating the middle or central portion 41 of the measuring probe 40 into or out of the measuring position. This axial shaft 51 is bored-through or hollowed-out along its length such as to accommodate not particularly shown connecting cables leading to a measuring means or device 54 provided in the middle or central portion 41 of the measuring probe 40. The turning or rotating movement is performed, for example, through an angle of approximately 45° between the positions shown in FIGS. 5 and 6.
In the travel position depicted in FIG. 5, a contact element or measuring wheel 53 of the measuring device or means 54, is located in an axial direction behind the guide wheel or wheel 10. However, the outer circumference of the contact element or measuring wheel 53 is arranged at a small distance from the wall of the measuring tube 1 and therefore does not engage the guide groove 12. The above-mentioned stop lugs 20 of the measuring tube 1 are each arranged on a respective side of the guide grooves 12, so that the measuring probe 40 can be unobstructedly displaced in the measuring tube 1 when the middle or central portion 41 assumes the travel position illustrated in FIG. 5.
When the contact element or measuring wheel 53 of the measuring device or means 54 passes the side of the rounded dome 38 of the piston 27 of the measuring cell 25 at the angular distance of 45°, and when correspondingly the counter stops 55, which are provided at the middle or central portion 41, pass the stop lugs 20 of the measuring tube 1, then the middle or central portion 41 is rotated by about 45° into the angular position illustrated in FIG. 6. The measuring probe 40 is then returned until the counter stops 55 arrive at exact engagement with the stop lugs 20, as is schematically illustrated in FIG. 4.
The exact engagement with the stop lugs 20 and therefore the exact alignment of the measuring probe 40 with the measuring tube 1 is ensured by means of the spherical construction of the counter contact surfaces formed at the counter stops 55 and the conical construction of contact surfaces formed at the stop lugs 20. The wheels or guide wheels 10 and 11 also assist in the accurate alignment of the measuring probe 40 and support the measuring probe 40 with a comparatively precisely adjusted bias in the guide grooves 12 of the measuring tube 1. This bias or spring bias is realized by mounting each of the wheels or guide wheels 10 and 11 at the ends of respective leaf or blade springs 57 and 58 as illustrated in FIGS. 11 and 12. The exact engagement or contact position in the rotary direction is ensured by means of contact bolts or pins 60 and 61 which are axially parallelly fixed in the related end portions 42 and 43 and engage in related circumferential grooves 62 and 63 of the middle or central portion 41 of the measuring probe 40. Each of the circumferential grooves 62 and 63 has opposite end surfaces as seen in the circumferential direction of the measuring probe 40. These end surfaces form stop surfaces for the related contact bolts or pins 60 and 61.
During the aforementioned return movement into the engagement or contact position, the contact element or measuring wheel 53 therefore moves underneath the rounded dome 38 of the piston rod or stem 28 and pushes outward, by a small amount relative to the measuring tube 1, the piston 27 which forms the pressure receiving component or sensing element of the measuring cell 25. During this movement, the measuring device or means 54 of the measuring probe 40 measures the force required therefor, i.e. the force necessary to maintain the piston 27, against the environmental pressure which acts upon its outside, out of engagement with the shoulder 32 of the housing 24 of the measuring cell 25. The contact element or measuring wheel 53 is mounted or journaled on an axle or shaft 66 fastened to the end of a lever 65 which extends parallel to the lengthwise axis of the measuring probe 40 and which is pivotable about a shaft 67 relative to the measuring probe 40. It is thereby achieved that the measuring wheel 53 when travelling under the measuring piston or piston 27, only moves substantially radially with respect to the measuring probe 40 or the measuring tube 1 and transmits the measuring force only in this direction to the measuring device or means 54. The pivot range of the lever 65 is very limited because the end of the lever 65 which carries the contact element or measuring wheel 53, abuts a transmitting member or force transmitting member 68 of the measuring device or means 54 and an impact bolt 69 is provided at the opposite end of the lever 65. The impact bolt 69 which is constructed as a threaded bolt with a locknut 70, so that the pivot range of the lever 65 can be radially outwardly adjusted.
The turning or rotating movement of the contact element or measuring wheel 53 when travelling under the piston 27, and the pivoting movement of the lever 65 are also freely rotatable due to a corresponding construction of the related mountings. This is also true for the piston 27 which is easily movable due to its mounting in the axial ball bearing 29.
The measuring device or means 54 is arranged in a longitudinally directed and cross-sectionally approximately square recess 70a of a solid main body 71 of the middle or central portion 41 of the measuring probe 40. This recess 70a is closed by a membrane 72 which is held at the main body 71 by means of a closure body 73 using bolts 74. The transmitting member 68 forms a closed frame 75 which is arranged in the recess 70a. The closed frame 75 encloses a measuring beam 76 and is fixedly connected with this measuring beam 76 by means of a bolt 77 and a locknut 78.
A threaded bolt 79 is fixed at the outside of the closed frame 75 of the transmitting member 68 and extends through an opening in the membrane 72 up to the end of the lever 65 which supports the contact element or measuring wheel 53. As a result, the transmitting member 68 can transmit the movement of the lever 65 or the deflection of the contact element or measuring wheel 53 to the measuring beam 76. A nut 80 is threaded or screwed onto the threaded bolt 79 and sealingly presses a washer 81, which encircles the threaded bolt 79, against the membrane 72 such that this membrane 72 is clamped between the closed frame 75 and this washer 81.
One end of the measuring beam 76 is tightly fixed by means of two bolts 84 and 85 to the solid main body 71 of the measuring probe 40 in such a manner that this end of the measuring beam 76 fixedly bears upon a raised bottom portion 86 of the recess 70a. The remaining portion of the measuring beam 76, for example, starting substantially from its center, is located at a small distance above a lowered or offset bottom portion 88 of the recess 70a. Consequently, the measuring beam 76 is bendable or deflectable due to the measuring movement of the transmitting member 68 which is fixedly connected with the measuring beam 76. An adjustment screw 89 which forms a stop, limits the bending or deflecting movement of the measuring beam 76. The adjustment screw 89 is enclosed by the bolt 77 which connects the measuring beam 76 with the frame 75 of the transmitting member 68. At maximum bending or deflection of the measuring beam 76, the end of the adjustment screw 89 comes to engage a bottom recess 90 formed in the recess 70a. This bottom recess 90 is provided for accommodating the bottom portion of the closed frame 75 which encloses the measuring beam 76. For example, a play or gap 91 of about 0.3 mm is set by adjustment of the adjustment screw 89.
The force measurement by means of the measuring beam 76 is achieved by determining its bending or deflecting deformation. This is achieved by externally mounting strain gauges 92A at one arm 76A of the measuring beam 76 in a specific bending or deflecting area or region 92 of the measuring beam 76. The strain gauges 92A are subject to changes in their electrical resistance under the action of strain. A suitable arrangement of the strain gauges 92A and their electrical circuit connection in the form of a Wheatstone bridge circuit enables high measuring precision. The area or region 92 of the measuring beam 76, where the bending or deflecting deformation or movement is measured, possesses a substantial cross-sectional weakening due to a cut-out 93 which extends in the longitudinal direction of the measuring beam 76 and which has an outward opening 94 at an end opposite to an outer free end 87 of the measuring beam 76. The cut-out 93 separates the one arm 76A from an other arm 76B of the measuring beam 76. Consequently, the measuring beam 76 possesses an inwardly directed or inner free end 95 at the other arm 76B and which extends parallel to the bending or deflecting area or region 92 of the one arm 76A. The closed frame 75 of the transmitting member 68 is affixed to this free end 95 or the other arm 76B in the manner mentioned hereinbefore. Consequently, the bending or deflecting deformation of this inwardly directed free end 95 is transmitted via the outer free end 87 of the measuring beam 76 to the bending or deflecting area or region 92.
An electrical cable which leads to the outside through the axial shaft 51, is designated by the reference numeral 96 and connects the strain gauges 92A with an electrical measuring instrument arranged on the outside. A portion of a cable 97 leading from the measuring probe 40 to the outside, is also shown in FIG. 4.
It will be understood that the force measuring arrangement described hereinbefore can also be constructed differently. For example, instead of the measuring beam 76 provided with strain gauges 92A, commercially available force sensors can be used which convert a measuring movement against the constant force of a spring element into an electrical measuring signal according to an ohmic resistive, capacitive, inductive or piezo-electric measuring principle.
FIG. 13 shows a second exemplary embodiment of the inventive measuring tube containing a sealing device 100. Compared to the use of the sealing means or collar 6 according to the illustration in FIG. 1, the sealing device 100 insures a more reliable and more complete sealing of the area or region in which the pressure measurement is intended. This is of great importance for a precise determination of the pressure in this area or region.
The sealing device 100 comprises a pair of sealing sleeves or collars 103 and 104 which are sealingly fixed to the outside of a measuring tube 101 via related flanges 102. The sealing sleeves or collars 103 and 104 are filled with a hardening filling medium, for example, cement mortar from outside a bore hole 106 by means of a filling conduit or line 105 in such a manner that they sealingly engage the bore hole wall 107. During this operation, the filling medium flows into the sealing sleeves or collars 103 and 104 through related filling valve mechanisms 109 and 110 which are clearly shown in FIG. 14 and which are placed inside the sealing sleeves or collars 103 and 104. Each filling valve mechanism 109 or 110 possesses a rubber elastic hose piece 114 which encircles a return conduit or line 111 and thereby a number of holes 113 provided therein. There is thus prevented a return flow into the return conduit or line 111.
The filled sealing sleeves or collars 103 and 104 between them seal off an enclosure or space 116 which subsequently is also filled, for instance, by a hardening filling medium 117. Since this latter filling medium 117 comes into immediate contact with the possibly uneven bore hole wall 107, there is achieved a sealing which is substantially improved when compared with the sealing merely achieved by the contact pressure of the sealing sleeve or collar 103 or 104.
A second filling conduit or line 119 with a return conduit or line 120 is provided for filling the enclosure or space 116. The return conduit or line 120 possesses inside the enclosure or space 116, a filling valve mechanism 122 which is constructed in the same manner as that already described in connection with FIG. 14. Furthermore, the return conduit or line 120 possesses a venting mechanism 123 containing a fabric sleeve or collar 124 fixed to the return conduit or line 120. The fabric sleeve or collar 124 surrounds a number of holes 125 in the return conduit or line 120 and permits the flow of air and/or water from the enclosure or space 116 to the return conduit or line 120 but holds back the filling medium 117 in the enclosure or space 116.
It will be understood that, with the exception of the measuring cell 25' which is provided at the end of the measuring tube 101, a sealing device 100 of the type described hereinbefore is provided in the longitudinal direction of the measuring tube 101 on each side of a measuring cell 25".
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly,
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A measuring tube is inserted into a bore hole for measuring underground fluid pressure and is sealed against the bore hole wall for limiting the areas or regions in which the pressure measurement is to occur. A measuring cell is inserted into the measuring tube wall in each of these areas or regions and includes a mobile pressure sensing element against which acts the pressure of the medium surrounding the measuring tube. An end of the pressure sensing element projects into the inner space of the measuring tube and, for measurement, a measuring wheel of a measuring probe is brought into position underneath the end of the pressure sensing element such that the latter is moved radially outwards against the pressure exerted on it. The force which thus acts on the measuring wheel is determined by a measuring device for measuring the pressure. The medium to be measured does not enter or leak into the measuring tube since the measuring cell is sealingly inserted into the measuring tube. The measuring wheel is brought very accurately into the measuring position by the rotation of a central portion of the measuring probe relative to the end portions, which are guided on wheels, and the movement of the probe until it makes contact with stops. This is a prerequisite for high precision pressure measurement.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/762,632 filed Apr. 19, 2010, which claims priority to U.S. Provisional Patent application No. 61/242,749 filed Sep. 15, 2009, the contents of which are each hereby incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The subject disclosure relates to pools and spas and more particularly to improved methods and apparatus for filtering contaminants from pools and spas.
[0004] 2. Description of Related Art
[0005] Portable spas have become quite popular as a result of their ease of use and multiplicity of features such as varied jet and seating configurations. One area where the inventor has recognized that ease of use could be enhanced is the area of maintaining proper water chemistry and sanitation.
SUMMARY
[0006] The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point tout the invention.
[0007] In an illustrative embodiment, water chemistry and sanitation are improved by installing a novel filter element in a filter compartment of a portable spa or tub In one embodiment, the filter element comprises a sintered plastic outer cylinder of a first diameter and a sintered plastic inner cylinder of a second diameter less than the first diameter. The inner cylinder is positioned coaxially with respect to the outer cylinder to define an annular interior chamber. A selected granular filter medium or media may then be placed in the annular chamber to combat one or more particular contaminants in the spa water.
[0008] In an alternative embodiment, a donut shaped bag containing selected filter media is placed in the annular chamber. In such an embodiment, the inner cylinder may be a suitable plastic mesh material and the bag may be adapted to hook over the inner cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic side sectional view of a portable spa;
[0010] FIG. 2 is a perspective view of an exchangeable media filter according to an illustrative embodiment;
[0011] FIG. 3 is a side sectional view of the filter of FIG. 2 taken at 3 - 3 of FIG. 2 ;
[0012] FIG. 4 is a side sectional view of an alternate embodiment.
[0013] FIG. 5 is a side sectional view of an alternate embodiment;
[0014] FIG. 6 is a side sectional view of an embodiment employing a resin filled bag;
[0015] FIG. 7 is a perspective view illustrating a mesh structure forming an inner cylinder in one embodiment;
[0016] FIG. 8 is a top view of a resin filled bag with a top hook feature;
[0017] FIG. 9 is a side sectional view of the bag of FIG. 8 ;
[0018] FIG. 10 is a side sectional view of a media filter embodiment employing the bag of FIGS. 8 and 9 ;
[0019] FIG. 11 is an exploded perspective view of another media filter embodiment;
[0020] FIG. 12 is a perspective view of the filter of FIG. 11 in an assembled state without media present between the mesh cylinders of the filter;
[0021] FIG. 13 is a perspective view of an end cap of the embodiment of FIG. 11 ;
[0022] FIG. 14 is a perspective view of the filter of FIG. 1 in an assembled state;
[0023] FIG. 15 is a perspective view of a baffled filter media bag embodiment;
[0024] FIG. 16 is a top view of the bag of FIG. 15 ;
[0025] FIG. 17 is a side view of an inner panel of the bag of FIG. 15 ; and
[0026] FIG. 18 is a side view of an outer panel of the bag of FIG. 15 .
DETAILED DESCRIPTION
[0027] FIG. 1 shows a first embodiment of a portable spa 11 containing an exchangeable media filter element 15 . The spa 11 includes a water circulation, purification and heating system, which includes a filter compartment or “filter bucket” 13 . In the system of FIG. 1 , spa water 29 passes through a circulation pipe 16 to a circulation pump 19 . A “T” junction 21 may be provided to supply water to a water feature such as a waterfall.
[0028] The circulation pump 19 further pumps the spa water through a “no fault” heater 22 , with which are associated a regulating sensor 23 and a hi-limit sensor 25 . An ozone generator and associated injector or other water purification apparatus 27 is also positioned in the return flow path to the spa 11 , which may comprise an 8 to 10 foot contact chamber 29 and a spa inlet 31 where a circulation return jet is created. A secondary drain 33 may also be provided. An electronic control unit 17 controls the pump 19 and ozone generator 27 , as well as other accessories which may be provided as part of the spa 11 . In one embodiment, the filter bucket 13 may be a conventional filter bucket traditionally manufactured as part of the original spa equipment.
[0029] An exchangeable media filter 15 according to an illustrative embodiment is shown in FIGS. 2 and 3 . The filter 15 includes inner and outer co-axially mounted annular filter cylinders 43 , 44 with a top cap 50 and a bottom cap 52 . The cylinders 43 , 44 are formed of sintered plastic, such as, for example, polypropylene or polyethylene. Other materials for the cylinders 43 , 44 may include, for example, and without limitation, PTFE (poly tetrafluoroethylene), PVDF (poly vinylidene fluoride), EVA (ethyl vinyl acetate) Nylon, thermoplastic polyurethane. The top and bottom caps 50 , 52 may be formed, for example, of plastisol, polyurethane, PVC, ABS, or Noryl, polypro, polyethylene, or chemically/thermally set plastic resin elastomer.
[0030] Presently preferred thicknesses W 1 , W 2 for each of the cylinders range from 1/16″ to ½″ with an exemplary thickness of ⅛″ for both W 1 and W 2 . Porosity of the cylinders may range from 25 to 150 microns, with 100 microns being a typical porosity. While the filter 15 is cylindrical, other geometrical shapes, such as square or star-shaped could be employed. Various heights and outer diameters may also be employed, including diameters of conventional filter elements such as, for example, 8 to 20 inches tall and 5 to 12 inches in outer diameter.
[0031] The respective filter elements 43 , 44 define an annular hollow inner chamber 47 . The annular chamber 47 constitutes a space which is filled with a selected granulated or beaded medium or combination of granulated or beaded media. Such media may include, for example, and without limitation:
Ion exchange resin De-ionization resin Zeolite Activated carbon Silver based media Ceramic Solid sanitizer (chlorine/bromine)
[0039] After filling the chamber 47 , the top cap 50 is fixed in place to close the unit. In operation, water flows radially from the outside larger diameter cylinder 43 to the inner cylinder 44 , at a flow rate of e.g. 1-10 gallons per minute, thus bringing the water in contact with the active media. An advantage of the illustrative embodiment is that cylinders containing different filter media can be added or exchanged after the spa has been filled with water in response to occurrence of a problem with a particular type of contaminant.
[0040] In use, when a spa is filled with water, there is an amount of contamination already in the water. Through usage, chemical addition, evaporation, and water addition; waste and other toxic elements can build up in the water. Traditionally, it is recommended to change the water when the total dissolved solids (TDS) exceed 1500 ppm, or based on a days of use measure; for example, according to the formula [(Spa size in gallons)/3] (times) (number of bathers per day)=the number of days before water change is needed.
[0041] A filter constructed according to the illustrative embodiments serves to extend the life of the water, reduce the number of water changes and save water by removing the accumulated TDS from the water. Such TDS include: toxic metals such as lead, iron, copper, manganese, minerals, calcium, magnesium, sodium, chloride, soaps, detergents, foaming agents, oils, suntan lotions, cyanuric acid, ammonia, pesticides, pharmaceuticals, organic acids, beer/wine, components of human sweat and waste, chlorinated by-products, humic acid, urine, body fluids, and tannins.
[0042] In an alternative embodiment, a screw-on cap is provided on a filter like that of FIG. 1 , enabling a user to change the media. In such case, the filter is removed from the spa, the top is unscrewed, and the media is replaced. In some embodiments the media may be limited to consumer friendly media like carbon, resin beads, and zeolites. As illustrated in FIG. 4 , such an embodiment may comprise two cylinders 143 , 144 with a potted bottom cap 152 . A ring 155 with internal threads 157 is provided, which is seated and bonded to the top of the outer cylinder 143 . The top cap 150 has external threads 159 , which permits the top cap 150 to be screwed onto the top of the filter 140 until an internal sealing surface 161 on an inner ring 163 of the top cap 150 contacts and seals with the inner cylinder 144 .
[0043] In an alternative embodiment, a press-fit or friction fit, rather than screw-on, cap is provided on a filter like that of FIG. 2 . As illustrated in FIG. 5 , such an embodiment may comprise two cylinders 243 , 244 with a potted bottom cap 252 . The top cap 250 has a grooved surface 259 , defining a groove 246 , which is dimensioned to press fittingly engage surface 243 . The internal sealing surface 261 on an inner ring 263 of the top cap 250 may also contact and press-fittingly seal with the inner cylinder 244 .
[0044] FIG. 6 illustrates an embodiment wherein the filter media 260 is contained within a donut-shaped or annular cross-sectioned bag 261 formed of a suitable water permeable, porous material. Such material may comprise, for example, polypropylene, polyester, cotton, rayon, polyethylene, nylon, PTFE (Teflon), polyacrylonitrile, or acrylic. In various embodiments, the fabric type may be woven, nonwoven, felt, or mesh of a thickness of, for example, 0.01″-0.25″. Illustrative porosities range from 10 microns to 500 microns.
[0045] In an embodiment such as FIG. 6 , the inner cylinder 144 may comprise a plastic net/mesh material 263 as shown in FIG. 7 , such as, for example, part No. 2370 as manufactured by Industrial Netting, Minneapolis, Minn. Additionally, in one embodiment, shown in FIGS. 8 and 9 , the donut bag 261 may have a fabric flange, flap, or hook 267 formed as a part thereof or attached thereto for purposes of slipping over the top rim or edge of an inner filter core. Thereafter, a top cap can be installed to hold the bag 260 in place, as illustrated in FIG. 10 . In one embodiment, an inner core or cylinder 244 of reduced height may be employed to accommodate the thickness of the fabric hook 267 .
[0046] In another embodiment of a filter 310 illustrated in FIGS. 11-14 , both an inner cylinder 311 and an outer cylinder 313 may comprise a plastic net or mesh material such as Part No. 2370 as manufactured by Industrial Netting, Minneapolis, Minn. In general the plastic mesh or net may comprise expanded or extruded plastic heated or ultra welded to form a rigid to semi-rigid mesh network. In various embodiments, the mesh network comprises openings of a uniform shape and size, for example, square, diamond, or rectangular. In one specific embodiment, the openings are square and 0.150 inches on a side.
[0047] Exemplary diameters for the inner and outer cylinders 311 , 312 may be 1½ to 3 inches and 5 to 10 inches respectively with 2½ inches and 6 inches being the dimensions of an exemplary embodiment. Such dimensions of course may vary in various embodiments. In one embodiment, the inner cylinder 311 may be extruded as a single seamless tube, whereas the outer cylinder 312 is extruded as a flat sheet and is then rolled and sealed along a vertical edge.
[0048] The filter of FIGS. 11-14 further includes a top cap 315 and a bottom cap 317 , which may be identical components in one embodiment. The caps 315 , 317 each include an inner circular channel 319 of rectangular cross-section and an outer circular channel 321 of rectangular cross-section, each of a width of, for example, 0.1 to 0.2 inches. The cylinders 311 , 313 are preferably potted into the bottom cap 317 , while the top cap 315 press-fits or friction-fits into place. In other embodiments, the cylinders 311 , 313 could be glued or snap fitted or otherwise attached to the end caps.
[0049] The inner circular channel 319 of the caps 315 , 317 is formed of two concentric cylinders 323 , 325 with the inner cylinder 323 having a height greater than the outer cylinder 325 in order to assist with alignment of parts during assembly. Similarly, the outer channel 321 is defined between concentric cylinders 327 , 329 where the inner cylinder 329 has a greater height for same purpose. The end caps 315 , 317 may be molded or otherwise fabricated of a suitable plastic such as, for example, ABS, PVC, acetyl, Delrin, polypropylene, polyethylene, polyurethane and/or plastisol.
[0050] Various filter media may be placed within the annular cavity defined between the inner and outer cylinders 311 , 313 . One such medium may be a spun bonded depth filter 316 . Such a filter may be formed, for example, of polyethylene, polypropylene, or nylon, and may be resin coated and sized to fit in between the inner and outer cylinder 311 , 313 . In other embodiments, porous bags of various suitable media described above may be formed as illustrated generally in FIGS. 6 , 9 and 10 and inserted into the annular cavity. In some embodiments, a spun bonded element such as element 316 and a porous filter media bag may both be used at the same time to achieve advantageous results. In one embodiment, a cylindrical spun bonded filter element may be positioned concentrically with a porous bag 351 , as shown in FIG. 19 .
[0051] The alternative fabric bag 351 is illustrated in detail in FIGS. 15-17 . The bag 351 includes inner and outer rectangular fabric components 353 , 355 , which are suitably sewn together to form a baffled structure 361 , which includes a plurality of vertical compartments 363 arranged in a circle. The bottom of each compartment 363 is first sewn shut, and each compartment 363 is then filled with a suitable medium or combination of media and thereafter sewn shut. In one embodiment, vertical stitching along lines 362 ( FIG. 18 ) is used to form the baffled compartments 363 . In other embodiments, the bag may be formed by ultra sonic or heat welding.
[0052] Suitable fabric materials for the bag may be the same as those for bag 261 of FIG. 6 . Suitable media for the bag may comprise silver media beads of various compositions, as well as various other media listed or discussed above.
[0053] Various embodiments of the filters according to FIGS. 11-18 are designed such that the inner cylinder 311 fits down and around a conventional filter stand pipe having a threaded top end such that a threaded cap or plug may be attached to the end of the stand pipe to hold the filter element 310 and its top cap 315 in place. One such embodiment is shown in FIG. 20 where the cylindrical or portion 366 of a cap 365 plugs through the central opening of top cap 315 . The interior of the cylinder 366 has threads which mate with those at the top end of a stand pipe 367 allowing the cap 365 to be screwed onto the stand pipe 367 . As the cap 365 is screwed down onto the stand pipe the circular flange portion 367 of the cap comes into flush abutment against the top cap 315 thereby further securing it in position. These and other mesh embodiments provide an easy-to-use filter wherein the filter elements can be easily removed for cleaning or replacement.
[0054] Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
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A filter element for a pool or spa including a sintered plastic outer cylinder of a first diameter, a sintered plastic inner cylinder of a second diameter less than said first diameter; the inner cylinder being position coaxially with respect to the outer cylinder to define an annular interior chamber; and a selected granulated filter medium or combination of media residing in the annular interior chamber.
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FIELD OF THE INVENTION
This invention relates to methods of manufacturing components with complex internal passages, including gas turbine components.
BACKGROUND OF THE INVENTION
It is difficult to manufacture components with complex internal geometries. Although precision investment casting is often used to manufacture components with internal cavities, the complexity of the passages is limited by the casting core and the ability to flow material within a mold. Intricate cores are fragile, and may not withstand the casting process. Machining of internal features is usually limited to line-of-sight processes.
There are various additive manufacturing techniques such as Direct Laser Metal Sintering (DMLS) that are capable of building components layer-by-layer from sintered powder. Although such techniques are suitable for making prototypes and for limited production, they are not economical for large scale production. Additionally, the surfaces of laser-sintered materials can be unacceptability rough.
In stacked laminate construction, a component is constructed from multiple layers of sheet or foil material. Each individual sheet can be easily machined to form cutouts. The component is then built by stacking the sheets. The sheets can be registered with the cutouts aligned to form complex internal geometries. A limitation of the stacked laminate approach is the ability to reliably bond each layer. Some materials such as superalloys Haynes® 230 and 282 that are otherwise desirable are difficult to bond into a laminated structure. This limits the choice of materials that can be used for laminated construction.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in the following description in view of the drawings that show:
FIG. 1 is a perspective view of a first sheet of material with a pattern of holes, including two registration holes.
FIG. 2 is a perspective view of a second sheet of material with a pattern of holes and two registration pins.
FIG. 3 shows stacking of sheets to form a stacked core structure with internal channels.
FIG. 4 shows a green-state casing preform surrounding a stacked core structure.
FIG. 5 shows the assembly of FIG. 4 after processing shrinkage of the casing.
FIG. 6 shows a fuel injector formed of a stacked core and casing.
FIG. 7 shows a casing preform sliding over a stacked core structure to form a fuel injector.
FIG. 8 shows the fuel injector formed from FIG. 7 , including a pressure plate.
FIG. 9 shows a fuel injector with air bypass clearance between the casing and the core structure.
FIG. 10 shows a cup-shaped casing embodiment with outlets.
FIG. 11 shows a segmented casing embodiment.
FIG. 12 shows a cup-shaped segmented casing embodiment with hoop.
FIG. 13 shows the casing of FIG. 12 after assembly.
DETAILED DESCRIPTION OF THE INVENTION
An aspect of the invention is a method of manufacturing components with complex internal features. The method utilizes a combination of two manufacturing technologies. A component core is made from a series of stacked sheets or foils, and an outer casing is manufactured using a process that compresses the casing on the core.
FIG. 1 shows a sheet of material 20 A with cutouts 22 A and registration holes 23 .
FIG. 2 shows a second sheet of material 20 B with corresponding cutouts 22 B and registration pins 24 . FIG. 3 shows a stack 25 of sheets 20 A- 20 F being assembled. The registration pins 24 fit into the registration holes 24 to register adjacent sheets so that cutouts 22 A align with or overlap the corresponding cutouts 22 B in adjacent sheets to define passages in the stack. Cutout patterns in each sheet may be formed using methods such as drilling/milling, laser cutting, water-jet cutting, stamping, and photochemical machining.
The registration pins 24 may be formed by molding, DMLS, or other methods. Alternately, the sheets may be registered in a jig or mold, and may be bonded together by a method such as diffusion bonding or adhesive. Alternately registration holes may be formed through every sheet in the stack 25 , and long registration pins may be inserted through all the sheets.
FIG. 4 shows a casing preform 28 that is placed or formed around a core stack 25 . The casing preform may be formed of a material that shrinks during processing. In this context the phrase “shrinks during processing” does not mean simply thermal contraction. It means permanent shrinkage as measured at the same temperature before and after processing. Examples of such materials are ceramic green-bodies and sinterable metal power mixed with a binder such as a polymer. Herein, “green body” or “green state” means a preform prior to processing shrinkage. The preform may be designed and dimensioned to shrink into compression upon the stack 25 as the casing preform is processed. The preform may be manufactured by injection molding or other methods. It may have one or more registration elements 30 that mate with corresponding elements 31 on the stack; for example tongue-and-groove elements. It may have an exterior mounting element(s) 32 .
FIG. 5 shows the casing 29 after processing, which reduces its volume, compressing the sheets of the core 25 together, and preventing their separation. The sheets may be bonded together or not, and may be bonded to the casing or not. Sintered metal and ceramic casings may develop a final density close to 100%. The casing may shrink up to about 20%, depending on the material. For sinterable powder materials, the shrinkage amount is largely determined by the particle constituents, their size/shape distribution, and the binder materials and proportion. These parameters may be selected in conjunction with the geometry and dimensions of the preform to produce a desired amount and distribution of compression on the sheets 20 A- 20 F.
FIG. 6 shows a gas turbine fuel injector 34 A made of a cylindrical stack 36 of sheets of material 20 in a casing 29 . Cutouts in the sheets align to form internal passages 38 for mixing fuel 40 and air 42 . A fuel and air inlet element 44 may be placed on one end of the stack. The casing 29 may span both the stack 36 and the inlet element 44 such that the casing compresses 46 the inlet element 44 against the stack 36 . The inlet element 44 may be tubular as shown or other shapes, and it may be formed by any method, such as casting or molding. Fuel ports 48 may pass fuel into the mixing passages 38 . Turbulators 50 may be provided in the mixing passages 38 to effectively mix the fuel and air. Stacked core structures for fuel injectors and other components may be designed in various shapes, including cylindrical, barrel-shaped, prismatic polyhedral, and irregular. An axis 51 is defined herein as a geometric central line normal to the planes of the sheets 20 . It may be an axis of rotational symmetry if the stack has such symmetry, but this is not a requirement of the invention. Herein “radial” means in a direction perpendicular to such axis.
FIG. 7 shows a geometry that allows the casing preform 28 to slide 52 over the stack 36 and the inlet element 44 . Inwardly extending lips 54 on the top end of the casing preform just clear the outer diameter of the stack 36 . Inwardly extending lips 55 on the bottom end of the preform are not so limited. FIG. 8 shows the resulting fuel injector 34 B after about 20% shrinkage of the casing. The green body casing may be designed to shrink a given amount such as 18-20% to allow clearance for sliding assembly. The dimensions of the preform may be designed to provide a uniform or non-uniform distribution of compression stresses around the stack 36 and the inlet element 44 . For example, the axial compression 46 may be greater than the radial compression 47 . A pressure plate 56 may be provided to distribute axial force from the lips 55 onto the end of the stack 36 . The pressure plate 56 may be for example at least twice as thick as an average sheet thickness among the sheets of the stack and may be formed of the same or a different material than the other sheets of the stack.
FIG. 9 shows a fuel injector embodiment 34 C with an air bypass clearance 58 between the stack 36 and the casing 29 that allows some air 59 to bypass the mixing channels 38 to provide near-wall cooling of the casing 29 or for other purposes. In this embodiment, the casing preform may be designed with an inner diameter large enough to leave the radial clearance 58 after shrinkage. Alternately, a fugitive material may be formed on the outer diameter of the stack, and a casing preform 28 may be bi-cast over the fugitive material, which may be chemically removed after sintering and/or other processing.
FIG. 10 shows a cup-shaped casing 29 having a bottom 60 with outlets 62 . These outlets may diverge from the inside to the outside surface of the casing 29 as shown to act as diffusers, and they may have a hexagonal shape as shown. One or more circular arrays of such outlets may be provided, and they may nest in a honeycomb pattern for space efficiency. Such a cup-shaped casing in green-body form may slide over the stacked core as shown in FIG. 7 .
FIG. 11 shows a segmented casing 29 with two or more segments 29 A, 29 B, 29 C rotationally symmetrically spaced around the circumference of the stacked core. Each segment spans a portion of the core. The lips 54 , 55 may extend inward as far as desired since they do not need to slide over the core as in FIG. 7 . The segments may fully encircle the sides of the stacked core. However, in the example of FIG. 11 , each of three segments 29 A, 29 B, and 29 C covers 60 degrees of cylinder, leaving 60 degrees between adjacent segments.
FIG. 12 shows a cup-shaped and segmented casing preform 28 , having a bottom 60 with outlets 62 as previously described. Side segments 28 A, 28 B, 28 C are separated by slots 64 . In this example there are four side segments, one of which is hidden. It is suggested that at least 4 segments be provided in this embodiment. This preform 28 can slide over the stacked core by flexing the segments outward, which allows the lips 54 to extend further inward than with a non-flexing preform. One or more hoops 66 may be formed of a material that shrinks during processing, particularly a sinterable material, and especially the same material as the casing. The hoops may be are compressed around the casing during processing in the embodiments of FIGS. 11 and 12 . Each hoop may be formed into a preform, slipped over the casing preform 28 after assembly of the preform onto the stack, and sintered with the casing or otherwise processed into compression thereon. FIG. 13 shows a hoop 66 assembled onto the casing 29 .
The process herein overcomes limitations associated with poor interfacial bond strength between sheet layers. A stacked sheet core of a component is encased within an outer casing. Precise, three-dimensional features can be produced in both the stacked core and the casing preform. These features may be designed to accurately fixture the components during processing and improve dimensional tolerances. A stacked core of a component can now be made of materials that have excellent heat tolerance or other desirable characteristics, but that are not easily bonded together, such as Haynes 230 and/or 282 superalloys.
While various embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions may be made without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
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Fabricating a core of a component ( 34 A, 34 B, 34 C) from a stack ( 25, 36 ) of sheets ( 20 ) of material with cutouts ( 22 A) in the sheets aligned to form passages ( 38 ) in the core. A casing preform ( 28 ) is then fitted over the core. The preform is processed to form a casing ( 29 ) that brackets at least parts of opposed ends of the stack. Shrinkage of the casing during processing compresses ( 46 ) the sheets together. The preform may slide ( 52 ) over the core, and may be segmented ( 28 A, 28 B, 28 C) to fit over the core. A hoop ( 66 ) may be fitted and compressed around the segmented casing ( 29 A, 29 B, 29 C).
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FIELD OF THE INVENTION
[0001] The present invention relates to identifying a type of drainage tile problem and localizing the problem.
BACKGROUND OF THE INVENTION
[0002] Drainage tile are essential parts of a drainage system in a field. They convey excess water from low spots so that the field remains fairly uniformly dry to enable field operations. If a tile line has a problem, which restricts the flow of water, areas of the field upstream from the problem will drain more slowly than normal after a rain or snow melt. A delay in drainage causes a delay in field operations while the water leaves the low spot by other means. Another problem with ineffective drainage is that damaged or dead crops may result from the roots being submerged in water for an excessive period of time, cutting off the normal flow of atmospheric gases to the roots.
[0003] Tile repair typically involves digging up the damaged section of the tile line, cleaning or replacing it, and then filling in the hole. If the problem spot cannot be precisely localized, a trial and error approach is often used in a suspected area of the problem. This approach can greatly increase the cost and time needed to effect the repair.
[0004] Boroscopes, with cameras can be pushed up a tile line to look for the problem, but this is typically only done after a problem has been identified. Further, this approach is expensive and requires expensive equipment and operational time.
[0005] What is needed in the art is a method and apparatus that will provide early and precise localization of drainage tile problems that minimize cost and impact on crops.
SUMMARY OF THE INVENTION
[0006] The invention comprises, in one form thereof, a method for identifying drainage tile problems in a field. The method includes the steps of detecting moisture levels at predetermined locations in the field, predicting moisture levels at the predetermined locations, and comparing the moisture levels detected in the detecting step with moisture levels predicted in the predicting step.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a farm field having many field nodes;
[0008] FIG. 2 illustrates a drainage tile pattern in the field of FIG. 1 ;
[0009] FIG. 3 illustrates localized field attributes in the field of FIGS. 1 and 2 ; and
[0010] FIG. 4 is a flowchart, illustrating an embodiment of a method for identifying and localizing drainage tile problems of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] Referring now to the drawings, and more particularly to FIG. 1 , there is shown a parcel of land or field 10 , suitable for agricultural use, and may be under agricultural cultivation or lying in a fallow state. Field 10 may be subjected to crop harvesting operations such as mechanized mowing, combining, plowing, planting as well as human hand picking and animal foraging. Numerous field nodes 12 are dispersed through field 10 and divide the parcel into several sample areas. While nodes 12 are illustrated as being uniformly positioned throughout field 10 , it can be understood that the positioning of field nodes 12 may be otherwise arranged.
[0012] Nodes 12 may be in the form of sensors 12 that provide information about localized attributes of field 10 . Sensor 12 is communicatively linked to a data gathering center, not shown, which may include a computerized recording and processing capability. Sensors 12 provide information such as soil temperature, moisture level, and vertical information relative to these attributes at various depths of soil at node 12 . Additionally, field nodes 12 may represent points of reference rather than sensor locations per say. For example, field nodes 12 may represent spatially defined positions that result from visual, penetrating radar, non-visual light observations, interaction of projected lasers upon positions represented by field nodes 12 , etc. Data received relative to field nodes 12 , whether from a sensor located at field node 12 or by way of an observed phenomenon at or about each field node 12 is gathered to provide information relative to soil conditions at field nodes 12 .
[0013] Now, additionally referring to Fig. 2 there is shown a drainage tile network located in field 10 including a tile outlet 14 and representative tile branches 16 , 18 , 20 , 22 , 24 and 26 . The drainage tile network is generally laid out so that water seeps into the tile network and flows along the various branches ultimately reaching tile outlet 14 . The layout of the tile network is such that it is normally considered a gravitationally flowed system regardless of the topology of the land thereby typically requiring surveying and elevational knowledge by the installer for the tile system to operate correctly. Tile branches 16 - 26 , as well as the rest of the tile system network are positioned across field 10 with many portions being proximate to various nodes 12 .
[0014] Now additionally referring to FIG. 3 , field 10 may have soil with varying soil attributes 28 , 30 , 32 , 34 and 36 which may relate to elevation, composition of the soil and moisture retention of the soil, etc. Soil attributes 28 - 36 illustrate that the present invention can operate with various soil attributes and provides interpretive procedures relative to the different soil attributes.
[0015] An aspect of modeling the moisture removal in field 10 includes understanding that water may leave field 10 in at least six manners. Once water enters field 10 by way of irrigation, water running onto field 10 , or most commonly by rain activity or snow melt, moisture is removed in some manner. Various manners in which water will leave field 10 include evaporation into the atmosphere, surface runoff, soil absorption, absorbed by plants in field 10 , drainage by way of the tile network through tile outlet 14 , or by subsoil absorption into the water table and/or aquifer. Evaporation into the atmosphere, may be modeled using an evapotranspiration modeling technique, which predicts the atmospheric evaporation based on such things as temperature, insolation, and humidity. Water runoff is often the function of the geography of field 10 as well as the amount of moisture capacity of the soil and the amount of water that comes into field 10 by any of the manners in which it could enter a field. The moisture content of the soil, the ability of the soil to absorb moisture, and the transmission of water from an underground source, such as a spring are other aspects of the movement of water into the tile network system of field 10 . The presence or absence of plants as well as the maturity of plants that are present in field 10 effect the amount of water that is absorbed thereby and utilized by the plants in their growing process. The tile system in field 10 allows for moisture to absorb through the subsoil by way of slots or holes in tile so that water entering tile branch 22 will flow along branch 22 and then merge with other branches ultimately reaching tile outlet 14 . The subsoil absorption of moisture as well as surface fun off also effect the movement of water in field 10 . Soil attributes can vary throughout field 10 as shown in FIG. 3 . For example, soil attributes 36 may include a highly clay ground which may poorly conduct water to tile branch 24 . Conversely soil attributes 32 may be of a sandy type soil allowing a quick conduction of moisture from this type of soil to the various branches of tile that pass therethrough.
[0016] A variety of in situ sensor technologies are available based upon U.S. Pat. Nos. 3,882,383; 5,424,649; and 5,430,384, which include soil moisture sensors that can be deployed to collect data with good spatial and temporal resolution. Data between the sensors can be interpolated using methods, such as inverse fourth power and other geostatistical methods. With this understanding, nodes 12 may be a data point for which a soil moisture sensor 12 is positioned or node 12 may be a data point that has been created in a interpolation method from information at other sensor points.
[0017] Now, additionally referring to FIG. 4 there is shown a flow chart of an embodiment of a method 110 of the present invention, including the step of providing a moisture level prediction matrix at step 112 , which includes a prediction of what a moisture level should be at each node 12 in field 10 based on the occurrence of moisture inputs into field 10 . For example, if a one inch rain has fallen upon field 10 over the past three hour period, this level of input is utilized to create the moisture level prediction matrix as to what the moisture level should be at each node 12 at various times following the one inch rain event. A second matrix is produced at step 114 which is a measured moisture data matrix that relates to measured moisture levels at each of field nodes 12 . The moisture level prediction matrix and the measured moisture data matrix are mathematically compared, for example, by way of calculating a difference matrix at step 116 . This can simply be an element by element subtraction of the first matrix from the second matrix to result in the difference matrix that is then subsequently evaluated. Large positive element values may indicate locations with significantly more measured moisture than predicted by the prediction methods of the present invention.
[0018] At step 118 interpretation of the difference matrix is undertaken. This may be done by a skilled observer or by software utilizing techniques such as pattern recognition, neural networks and/or fuzzy logic. Additionally, a combination of human and automated techniques may be utilized to interpret the difference matrix. The interpretational techniques also can utilize additional information such as digital elevation maps showing water flow, a 3-D soil map, which may include information about soil attributes 28 through 36 , a tile map such as that illustrated in FIG. 2 , and information relative to field machinery traffic. Since soil attributes in field 10 may include variations in elevation, the tile depth relative to the elevation is also a factor to predict the amount of water flow in the tile branches.
[0019] Some interpretive results include the detecting of high moisture readings as illustrated by an interpretation of the difference matrix showing a sharp rise along a tile branch as the data is analyzed moving up the line along the tile route. If the readings are not high along neighboring parallel tile lines, for example branch lines 20 and 22 , then a blockage likely exists at the intersection of the rise in moisture levels and the tile branch. More specifically, if tile branch 22 has a relatively higher moisture reading therealong than tile branch 20 , it could be concluded that there is a blockage in tile branch 22 that is either slowing the exit of water therefrom or it may be completely blocked not allowing any water to flow through tile branch 22 . The information at field nodes 12 proximate to tile branch 22 can be interpolated to provide a position that is estimated based on the values at nodes 12 , thereby localizing the area in which the blockage exists.
[0020] Another interpretive method relates to a very localized rise in measured soil moisture, which does not extend up-line along the nearest tile lines then this reading may be a faulty sensor or inaccurate sensor reading.
[0021] Yet another interpretation is if there is a substantially high difference between the predicted and measured moisture across the entire field, then the problem may exist at tile outlet 14 . If tile outlet 14 is not actually an outlet to a surface location but rather continues on then it may also be concluded that the obstruction or blockage is downstream from tile outlet 14 .
[0022] Yet another interpretation which may result from executing step 118 is that if a uniformly high moisture level is measured near the soil surface versus a deeper level, such as close to the tile line depth and that there has been major field work since the last major rain or irrigation event, then the field work may have created a compacted layer, such as a clay pan, that is impeding the water flow from the upper layers of soil past the compaction level to the tile in subsoil levels. This may indicate the need for tillage to take place to an appropriate depth to break up the compaction layer. As can be seen the interpretive results can determine blockage levels in the tile lines, soil conditions and sensor problems.
[0023] The information interpreted in step 118 is output at step 120 to a user if the information at step 118 is the result of a computing algorithm contained in a computing machine. The output may include information relative to recent water inputs into field 10 along with information about potential localized blockages in the drainage tile system. Computer graphics and other output techniques may be utilized. The information may include coordinates for the predicted problem, which can be used with a GPS system or interaction with sensors 12 to find the problem area.
[0024] Method 110 can be additionally utilized if the information received about field nodes 12 is developed in another manner. For example, relative surface soil moistures can be measured visually. This is most practical in the spring before crops emerge and the tile lines are especially visible using infrared and other lightwave techniques. The surface images are collected using ground vehicle mounted cameras, aerial cameras and/or satellite borne cameras. The visual information is utilized to generate a calibrated individual or plurality of ground maps over periods of time, where intensity of changes of reflected light correspond to soil moisture changes. For example, an abnormal darkness in one area of field 10 may indicate a higher moisture level. The soil model generates a matrix of information relative to field nodes 12 , where each element corresponds to an expected soil surface color based on soil type, soil color being reflective of a of moisture level that relates to that soil color. This may vary across field 10 and soil attributes 28 through 36 are considered in the model so that one reflected color in one section such as soil attributes 28 may vary from soil attributes 30 and are thereby compensated for in the interpretive method of the present invention. This is done by utilizing the known difference of colors that equate to different moisture levels. The camera data is then utilized to generate the second matrix where elements have measured soil moistures for the corresponding field nodes 12 in the field 10 . The first matrix and the second matrix are then mathematically compared, for instance creating a difference matrix as in step 116 to compare the expected colors of soil versus the measured colors of soil. It should be noted that other methods of projecting light and/or radar waves upon field 10 can also be utilized to generate matrix data that is similarly interpreted.
[0025] A time sequence of matrices can be utilized to record the expected drying sequence. For example, historical information based on a series of sequential matrices can be utilized to predict expected outcomes from similar rainfall and/or irrigation events. The predictive method of the present invention compensates for the speed of drying that may be due to evapotransporation factors to more accurately predict the flow of water through the drainage tile system. This is helpful in situations where the problem is a partial obstruction rather than a blockage. The time sequential series predicts a trending for the moisture removal from field 10 and if a certain section of field 10 , such as along tile branch 26 does not dry at the predicted speed of drying then it can be inferred that there may be a partial obstruction, which can then be addressed if the field is not planted or may be delayed until after a crop is harvested so that maintenance can be done with minimal damage to the crop. This advantageously allows for a more sensitive prediction of problems before a full blockage occurs.
[0026] Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims.
ASSIGNMENT
[0027] The entire right, title and interest in and to this application and all subject matter disclosed and/or claimed therein, including any and all divisions, continuations, reissues, etc., thereof are, effective as of the date of execution of this application, assigned, transferred, sold and set over by the applicant(s) named herein to Deere & Company, a Delaware corporation having offices at Moline, Ill. 61265, U.S.A., together with all rights to file, and to claim priorities in connection with, corresponding patent applications in any and all foreign countries in the name of Deere & Company or otherwise.
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A method of identifying drainage tile problems in a field including steps of detecting, predicting and comparing moisture levels. The steps including detecting a moisture level at predetermined locations in the field; predicting moisture levels at the predetermined locations; and comparing the moisture levels detected in the detecting step with the moisture levels predicted in the predicting step.
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BACKGROUND OF THE INVENTION
This invention relates to a fuel injection nozzle unit for internal combustion engines such as diesel engines, and more particularly to a fuel injection nozzle unit capable of controlling the lift of the nozzle needle.
It is generally required to vary the injection rate through an injection nozzle in order to maintain proper combustion conditions of an internal combustion engine over various operating regions of same, and the most effective way of varying the injection rate is to control the lift of the nozzle needle. A fuel injection nozzle unit adopting this concept of controlling the lift of the nozzle needle is already known, e.g., from Japanese Provisional Utility Model Publication (Kokai) No. 57-172167.
However, the conventional fuel injection nozzle unit is difficult to fabricate and too large in axial size, since it is constructed such that the lift of the nozzle needle is controlled by rotating a lift adjusting screw to change the axial position of a stopper for the nozzle needle.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a fuel injection nozzle unit for internal combustion engines which is simply and compactly constructed but is capable of precisely controlling the lift of the nozzle needle.
The present invention provides a fuel injection nozzle unit for an internal combustion engine, including a nozzle body having injection holes and a pressure chamber formed therein, a nozzle needle fitted in the nozzle body for lifting to open the injection holes, a nozzle spring urging the nozzle needle in a direction of closing the injection holes, and a central plunger having one end thereof arranged opposite one end of the nozzle needle at a distance corresponding to a predetermined lift, and liftable together with the nozzle needle when the predetermined lift is exceeded, wherein the nozzle needle is lifted by a fuel pressure supplied to the pressure chamber to effect fuel injection. The fuel injection nozzle unit according to the invention is characterized in that it comprises a piezo-electric element provided around the central plunger, and means for selectively electrically energizing and deenergizing the piezo-electric element, the piezo-electric element being radially deformable in response to energization or deenergization thereof to allow or inhibit lifting of the central plunger.
The above and other objects, features and advantages of the invention will be more apparent from the ensuing detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a fuel injection nozzle unit according to a first embodiment of the invention;
FIG. 2 is an enlarged perspective view of the piezo-electric element of FIG. 1;
FIG. 3 is a graph showing curves for the fuel rate characteristics of the fuel injection unit according to the invention;
FIG. 4 is a transverse cross-sectional view of a fuel injection nozzle unit according to a second embodiment of the invention;
FIG. 5 is a longitudinal sectional view of a fuel injection nozzle unit according to a third embodiment of the invention; and
FIG. 6 is an enlarged perspective view of another example of piezo-electric element employed in a unit according the invention.
DETAILED DESCRIPTION
The invention will now be described in detail with reference to the drawings showing embodiments thereof.
Referring first to FIGS. 1-3, a first embodiment of the invention will be explained. FIG. 1 shows a fuel injection nozzle unit A for internal combustions engines according to the invention, wherein reference numeral 1 designates a nozzle holder, by which is supported a nozzle body 3 by means of a retaining nut 4 threadedly fitted on the nozzle holder 1, with a distance piece 2 interposed between the nozzle holder 1 and the nozzle body 3. A nozzle needle 6 is axially slidably fitted in an axial bore 5 formed in the nozzle body 3. The nozzle needle 6 has a pressure stage 6a at an intermediate portion thereof, from which extend an upper half having a larger diameter and a lower half having a smaller diameter. The pressure stage 6a is normally located within a pressure chamber 7 formed in the nozzle body 3. A seating face 6b formed at the lower end of the nozzle needle 6 is normally seated on a seating face 3a formed at the lower end of the nozzle body 3, to close and open injection holes 8 formed in the lower end of the nozzle body 3 as the nozzle needle 6 is reciprocatingly moved. To be specific, the nozzle needle 6 is liftable in response to an increase in the pressure of fuel in the pressure chamber 7 to open the injection holes, and seatable on the seating face 3a to close them when it is in its lowest position, as shown in FIG. 1.
Secured on top of the nozzle needle 6 is a head pin 9 which extends loosely through a small central hole 2a formed in the bottom of the distance piece 2 and is provided at its upper end with a movable spring seat 10 arranged in a recess 2b formed in the distance piece 2.
A nozzle spring 11 is accommodated within a spring chamber 13 defined within the nozzle holder 1, with its lower end supported by the movable spring seat 10 and its upper end supported by a stationary spring seat 14 attached to a stepped shoulder 12 defining an upper end wall of the spring chamber 13, thus urging the nozzle needle 6 downward, i.e., in a direction of closing the injection holes via the movable spring seat 10.
A central plunger 15, which is a lift control member, is axially slidably provided in the nozzle holder 1. The central plunger 15 has an upper half 15a having a larger diameter and a lower one 15b having a smaller diameter, with an intermediate stepped shoulder 15c formed at the border therebetween. The thicker portion 15a is fitted in an axial bore 16 axially extending upward from the stepped shoulder 12, with a diameter smaller than that of the spring chamber 13, while the thinner portion 15b of the central plunger 15 axially extends downward through a central hole 14a of the stationary spring seat 14 into the spring chamber 13 of the nozzle holder 1. The lowest position that the central plunger 15 can assume is determined by the stationary spring seat 14 whose upper surface abuts with the stepped shoulder 15c of the central plunger 15.
When the central plunger 15 is in its lowest position, its lower end face and the upper end face of the movable spring seat 10 face each other with a gap L1 for initial injection lift therebetween, while the upper end face of the nozzle needle 6 and the opposed lower end face of the distance piece 2 define therebetween a gap L2 for total lift.
Provided around the thicker portion 15a of the central plunger 15 is a piezo-electric element 17, which, as shown in FIG. 2, is in the form of an annulus and disposed to radially contract when electricity is applied to electrodes 18 provided on one end face of the annulus. The piezo-electric element 17 has a multi-layered structure having a plurality of annular layers fitted one over another. Alternatively, it may be formed of a single layered structure. Furthermore, although in FIG. 2 the layers are radially superimposed one upon another, the same effect may also be obtained if the layers are axially superimposed, as shown in FIG. 6. The piezo-electric element 17 is fitted in an annular groove 19 formed in the inner peripheral wall of the axial bore 16 in the nozzle holder 1, and the thicker portion 15a of the central plunger 15 penetrates a central through hole 17a formed in the piezo-electric element 17. The diameter of the central through hole 17a of the central plunger 17a is set at such a value as to be slightly greater than the outer diameter of the thicker portion 15a of the central plunger 15 when electricity is applied to the electrodes 18. On the other hand, when energized through the application of electricity to the electrodes 18, the piezo-electric element 17 radially contracts to reduce the diameter of the central hole 17a whereby the inner peripheral wall of the annulus squeezes the thicker portion 15a of the central plunger 15 to prevent the central plunger 15 from lifting. When the piezo-electric element 17 is deenergized, the annulus expands to its original size to restore the original diameter of the central hole 17a to thereby allow the central plunger 15 to lift. The lower end face and the outer peripheral surface of the piezo-electric element 17 are covered with a soft protective sheet 20. The electrodes 18 of the piezo-electric element 17 are electrically connected via conductor wires 21 to an electronic control unit (not shown), which is supplied with signals indicative of various engine operation parameters required for controlling the fuel injection, such as engine rotational speed, engine load, engine coolant temperature, and exhaust gas temperature, from respective engine operation parameter sensors, not shown, and outputs a control signal, which is determined on the basis of these input signals, for selectively energizing or deenergizing the piezo-electric element 17 to obtain injection rates optimal to operating conditions of the engine.
The axial bore 16 in the nozzle holder 1 communicates with a fuel inlet 1a provided in top of the nozzle holder 1 and continuous with the axial bore 16. The fuel inlet 1a is connected to a fuel injection pump via an injection pipe, neither of which is shown, so that the central plunger 15 receives at its upper end face the pressure of fuel supplied from the fuel injection pump. Also, the pressure chamber 7 is in communication with the axial bore 16 via passages 22, 23, and 24 formed, respectively, in the nozzle body 3, the distance piece 2, and the nozzle holder 1, the passage 24 opening into the axial bore 16 at a location above or upstream of the top of the central plunger 15, as seen in FIG. 1.
The fuel injection nozzle unit of the invention constructed as above operates as follows:
Pressurized fuel delivered from the fuel injection pump enters the axial bore 16 through the fuel inlet 1a to be delivered into the pressure chamber 7 through the passages 24, 23, and 22 in this order. The incoming fuel flow causes an increase in the fuel pressure within the pressure chamber 7, which in turn acts upon the pressure stage 6a (having a sectional area As) of the nozzle needle 6. When the fuel pressure P1 within the pressure chamber 7 rises to overcome the urging force F1 of the nozzle spring 11 (P1 F1/As), that is, when it reaches an initial valve opening pressure, the nozzle needle 6 is lifted through the gap L1 for initial injection lift against the urging force of the nozzle spring 11, whereupon the seating face 6b of the nozzle needle 6 leaves the seating face 3a of the nozzle body 3, to thereby effect a low rate injection through the injection holes 8. Then, let it be assumed that the piezo-electric element 17 is deenergized by ECU. If the engine is in a high speed region, the fuel pressure within the pressure chamber 7 further increases so that the relationship P F/(An-Ac) is established, where F is the force of the nozzle spring 11 after being compressed by the gap L1, Ac is the cross-sectional area of the upper thicker portion of the central plunger 15, P is the fuel pressure, and An is the cross-sectional area of the upper thicker portion of the nozzle needle 6, that is, the fuel pressure reaches a main valve opening pressure, whereupon the nozzle needle 6 is lifted together with the central plunger 15 through the gap L2-L1 for main injection lift against the force of the nozzle spring 11 and the pressure force of the pressurized fuel in the axial bore 16 to thereby effect a high rate injection through the injection holes 8.
On the other hand, if the piezo-electric element 17 is energized, it radially contracts to thereby keep the central plunger 15 from being lifted from its lowest position as shown in FIG. 1, even after the above low rate injection is effected. Thus, even when the pressure within the pressure chamber 7 is increased above the initial valve opening pressure, the nozzle needle 6 is kept in its initial lift position, so that only the low rate injection is continued. As noted above, with the piezo-electric element 17 deenergized, the injection characteristic will be such as is shown by the solid curve in FIG. 3, which is obtained by a conventional fuel injection nozzle unit of this kind equipped with a central plunger, whereas with the piezo-electric element 17 energized, the injection characteristic will be such as shown by the broken curve in FIG. 3, wherein the low rate injection is continued as long as the piezo-electric element 17 is energized.
Although in the above described embodiment the method of the invention is applied to a fuel injection nozzle unit of a type wherein the injector is connected to a fuel injection pump by way of an injection pipe, the method is also applicable to a unit injector wherein a plunger for pumping out pressurized fuel, which forms part of a fuel injection pump, and a fuel injection nozzle are combined in one body and mounted in the cylinder head.
FIG. 4 illustrates a unit injector of such a type that the injection beginning and the injection end are determined by opening and closing a solenoid valve, and to which the method of the invention is applied. In FIG. 4, corresponding elements and parts to those in FIG. 1 are designated by identical reference characters. In the figure, reference numeral 30 designates a main body of the unit injector, incorporating a plunger barrel 32 by which is supported at its lower end an injection nozzle unit A according to the invention. A pumping plunger 34 is slidably fitted in an axial through bore 33 of the plunger barrel 32. As a rotating cam, not shown, in slidable contact with a cover 35 is rotatively driven by an internal combustion engine, not shown, the cover 35 is reciprocatingly moved together with a spring seat 36 serving as a tappet, the plunger 32 held by the spring seat 36 is forced to make reciprocating movement through the axial bore 33, with the aid of a plunger spring 37, sucking fuel into a plunger chamber 40 through a fuel inlet 38 and a fuel supply port 39 during its lifting stroke, and pressurizing, during its descending stroke, the fuel within the chamber 40 after blocking the fuel supply port 39 with its outer peripheral surface, when a drain or overflow port 41 is closed by a solenoid valve 42 to thereby force the fuel into a pressure chamber 7 through passages 24, 23, and 22 in this order. When the fuel pressure within the pressure chamber 7 reaches an initial valve opening pressure, the nozzle needle 6 is lifted through the gap L1 for initial injection lift to thereby open nozzle holes 8 to effect a low rate injection through the injection holes 8, similarly as in the embodiment of FIG. 1. Then, if the piezo-electric element 17 is deenergized, as the fuel pressure in the pressure chamber 7 rises to reach a main injection valve opening pressure, the nozzle needle 6 is lifted through the gap L2-L1 for main injection lift to thereby cause a high rate fuel injection through the injection holes 8, like the embodiment of FIG. 1. On the other hand, if on this occasion the piezo-electric element 17 is energized, the low rate fuel injection continues.
Now, if the drain port 41 is opened by opening the solenoid valve 42, the pressurized fuel within the plunger chamber 40 escapes through the drain port 41 and an outlet 43 into a fuel tank, not shown, whereby the pressure within the plunger chamber 40 and hence the pressure within the pressure chamber 7 suddenly drop to allow the nozzle spring 11 to return the nozzle needle 6 into its valve closing position, hence the injection terminates.
As stated above, although according to the embodiment of FIG. 4, the pumping plunger 34 only reciprocates without rotating, and the injection beginning and the injection end are controlled by opening and closing the solenoid valve 42, the application of the method of the invention is not limited to this type, but the method of the invention may be applied to such a type as shown in FIG. 5, wherein the pumping plunger 34 is disposed to rotate as well as reciprocate, and a control rack connected to a governor (neither of which is shown) causes the plunger 34 to rotate so as to change the time the fuel is allowed to overflow during the descending stroke of the plunger 34, whereby the fuel delivery quantity is controlled. According to the embodiment of FIG. 5, the pumping plunger 34 is provided with a pinion 44 which meshes with a control rack, not shown, to be driven thereby to change the circumferential position of the former with respect to the main body 30, hence operation of the control rack causes a rotation of the pumping plunger 34, to thereby control the effective delivery stroke thereof, i.e., the fuel delivery quantity. Incidentally, in FIG. 5, reference numerals 45a and 45b designate, respectively, a plunger helix and a vertical groove formed in the outer peripheral wall of the pumping plunger 34, and 46a and 46b designate, respectively, a fuel outlet and a fuel inlet provided in the unit injector body 30, which are in communication with the plunger chamber 40 by way of a port 47 formed in the main body 30, an annular suction gallery 48 defined between the outer peripheral surface of the plunger barrel 32 and the inner wall of the retaining nut 4, and an intake port 49 formed in the plunger barrel 32. During the lifting stroke of the pumping plunger 34, fuel is drawn through the suction gallery 48 and the intake port 49 into the plunger chamber 40, and during its descending stroke, after the intake port 49 is blocked by the outer peripheral surface of the plunger 34, the fuel drawn into the plunger chamber 40 is pressurized, and when its pressure reaches the valve opening pressure, fuel is injected in the same manner as in the embodiment of FIG. 4. When the intake port 49 is put in communication again with the plunger chamber 40 by way of the vertical groove 45b the pressure within the plunger chamber 40 suddenly drops whereby the nozzle needle 6 closes the valve to terminate the injection.
Since the other elements and parts in FIG. 5 are identical in construction and function with corresponding parts of the embodiments of FIG. 1 and FIG. 4, they are designated by identical reference characters, and description thereof is omitted.
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In a fuel injection nozzle unit, a piezo-electric element is provided about a central plunger for controlling the lift of the nozzle needle to selectively inhibit and allow lifting of the central plunger by having its inner diameter decreased or increased in response to electrical energization or deenergization thereof, thereby adjusting the fuel injection rate characteristic.
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SUMMARY AND BACKGROUND OF THE INVENTION
This invention relates to a thin and flat keyboard structure.
As disclosed in earlier applications Nos. 16,075 on Feb. 28, 1979 and 33,414 on Apr. 14, 1979 both entitled METALIC HOUSING FOR AN ELECTRONIC APPARATUS WITH A FLAT KEYBOARD, the applicant of this application has proposed a new type of a keyboard which takes advantage of part of an upper member of a housing as key actuators or key tops. Cutouts are each formed around the whole periphery of a respective one of limited areas of a housing member except for a hinge section, the respective limited areas defined by the cutouts behaving as the key actuators. Since the housing member and the key actuators are both made from the same material and it is difficult to work the key actuators independently of the housing member, the above mentioned attempts are still unsatisfactory in that neither distinction between the key actuators and the housing member nor the positions of the key actuators itself are ambiguous and an objectionable gap occurs between the housing member and the key actuators, thus presenting the possibility that the edges of the key actuators may be scratched by the operator's finger and sometimes become warped in the upward direction. The suggested keyboard in which the hinge sections remain is of a practical advantage in that the key actuators may be integral with the housing member but has difficulty in obtaining an appropriate key load in view of the necessary strength of the housing, etc.
Accordingly, it is an object of the present invention to provide an improvement in the earlier filed keyboards in which two metallic sheets with a very thin thickness are employed to constitute an upper member of the housing and the key actuators.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further objects and advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is an exploded perspective view, partially in section, of one preferred form of the present invention;
FIG. 2 is a perspective view of how to assemble the components shown in FIG. 1;
FIG. 3 is a rear view of an upper member of the housing;
FIG. 4 is a cross sectional view taken along the line A--A of FIG. 3;
FIG. 5 is a front view of an integral key actuator sheet;
FIG. 6 is a partly enlarged cross sectional view of FIG. 5; and
FIG. 7 is a cross-sectional view taken along the line D--D of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2, there are shown an exploded perspective view and a cross sectional view illustrating one preferred form of the present invention when applied to a hand-held calculator. An upper member 1 of the housing is made from a metal such as stainless steel and aluminum and has apertures 2 each corresponding to a respective one of the key actuators. A lower member 3 of the housing is likewise made of metal. A key actuator sheet 4 is also made from a metal material and more preferably a highly flexible metallic sheet such as stainless steel and phospher bronze. The respective key actuators 5 are made integral with the key actuator sheet 4 and are defined by cutouts 6a, 6b, etc. When the upper member 1 of housing is stacked on the key actuator sheet 4, the upper faces of the respective key actuators are exposed to the outside world through the apertures. A key contact rubber sheet 7 and a key circuit board 8 carry opposing key contacts 9 and 10. A pressure plate 11 is provided to urge the key circuit board 8 against the upper member 1 of housing together with the key actuator sheet 4 and the key contact rubber sheet 7 as well as serving as a reinforcing member for the hand-held calculator. In FIG. 2, key indicia formed on the tops of the key actuators 5 are labeled 12.
Details of the upper member 1 of the housing are illustrated in FIGS. 3 and 4 with the former being a rear view and the latter being a cross sectional view taken along the line A--A of FIG. 3. As stated briefly above, the upper member 1 of housing is made of a stainless steel sheet of 0.2 mm thick and subject to various processes such as etching. Key actuator sections 13 (corresponding to the key actuators sheet 4 when being stacked) are concave shaped with a thickness of 0.1 mm and has a predetermined number of the apertures 2 formed therein. A thick thickness section 14 is provided with a viewing window 15 for a display, for example, a liquid crystal display cell.
The whole top surface (the surface B in FIG. 4) of the upper member of the housing is coated with a layer of etching resist material except for the apertures 2 and the viewing window 15. The rear surface (FIGS. 3 and 4C) is also overlaid with a layer of etching resist material except for the corresponding key actuator sections 14 and the viewing window 15. Both the top and bottom surfaces are subjected to etching up to a depth of 0.1 mm. After the removal of the etching resist material the upper member 1 of the housing, as discussed above, results.
Details of the key actuator sheet 4 are depicted in FIGS. 5 through 7 wherein FIG. 5 is a front view, FIG. 6 is an enlarged view of the key actuator 5 with two cutouts 6a and 6b and FIG. 7 is a cross-sectional view taken along the line D--D of FIG. 6. As stated above, the key actuator sheet 4 is made from, for example, a phosphor bronze sheet of 0.2 mm thick and subjected to various processes such as etching. The key actuator section 5 is 0.2 mm thick and all of remaining sections are substantially 0.1 mm thick so that the former is convex as a whole and surrounded by the cutouts 6a and 6b. The cutouts 6a and 6b, as viewed from FIG. 6, are not contiguous to each other and thus establish key actuator supports 16a and 16b of a given length along the length of the key actuator 5. The key actuator 5 may be thus made integral with the key actuator sheet 4 and given flexibility to reduce load when being actuated, so that the key actuator is movable upward and downward without tilting itself.
One way of manufacturing the above described keyboard will be discussed below. The key actuator section 5 at the front face (the surface E in FIGS. 5 and 7) of the metallic sheet is first covered with the etching resist layer while the rear face thereof is covered with the same etching resist layer wholly except for the cutouts 6a and 6b.
Etching is allowed to progress up to a depth of 0.1 mm. The subsequent removal of the front and rear etching resist layers results in the above illustrated key actuator sheet 4. When it is desired to define key actuator indicia 12 by etching, the portion of the etching resist layer corresponding to these indicia should remain for printing.
If the resulting upper member 1 of the housing is laid upon the key actuator sheet 4, they both look like a single metallic sheet in the aggregate as viewed from FIG. 2. In this case, when the both elements are made of a different in material (in the above illustrated example, stainless steel and phospherus bronze), they can be distinguished in color, etc. from each other and the respective positions of the key actuators are clear. Although not shown in the drawings, it is obvious that it is possible to treat the respective surfaces differently with grinding or otherwise to distinguish the surface states between both of the elements and make the respective positions of the key actuators clear, even when the upper member of the housing and the key actuators are made from the same material, for example, stainless steel. Moreover, since the key actuator sheet member 4 is distinct and separate from the upper member 1 of housing, it is also possible to implement the former with a highly flexible metallic sheet without reducing the overall strength of the keyboard construction. The cutouts 6a and 6b are concealed behind the bottom of the upper member 1 of the housing without imparing the appearance of the keyboard construction. This makes it possible to form the cutouts in any desired pattern, assure an optimum load when a key is actuated, prevent the edges of the key actuators from being scratched by the operator's finger and becoming warped in the upward direction and reduce the spacing between the key actuators and the upper member 1 of the housing to a minimum.
Otherwise, in the case where the upper member 1 of the housing and the key actuator member 5 are made from a metallic sheet, the resulting keyboard construction becomes tough and thin as well as serving as an electrostatic shield. Key indicia may be printed by etching at the time the cutouts are formed in the metallic sheets.
Whereas the present invention has been described with respect to specific embodiments thereof, it will be understood that various changes and modifications will be suggested to one skilled in the art, and it is intended to encompass such changes and modifications as fall within the scope of the appended claims.
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A keyboard construction including a metallic flat housing member and a metallic flat key actuator member closely laid upon the metallic flat housing member. The former has apertures in positions to correspond to respective ones of key actuator sections while the latter has cutouts to make respective ones of key actuators formed therein movable in a vertical direction. Key indicia are defined on the tops of the respective key actuators during the etching of the two members.
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[0001] This patent application is a continuation of U.S. patent application Ser. No. 10/613,499 filed Jul. 3, 2003, entitled “Variable-Mechanical-Impedance Artificial Legs” which claims priority to and the benefit of U.S. Provisional Patent Application No. 60/395,938, filed Jul. 15, 2002, entitled “Variable-Mechanical-Impedance Artificial Legs” the entire contents of each of which is hereby incorporated by reference in their entirety.
[0002] The invention relates generally to the fields of legged robotics, orthotic leg devices and prosthetic leg joints, and more specifically to artificial limbs with time-variable mechanical parameters.
BACKGROUND
[0003] Prosthetic limbs have come a long way since the days of simple wooden “peg legs”. Today, amputee men running on a prosthetic leg can beat race times of the best unimpaired women runners. It is believed that new advances in prosthetic limbs (such as those embodied in the present invention) will soon lead to amputees being able to out-perform the best unimpaired athletes of the same sex in sports such as running. It is an object of the present invention to advance the state of prosthetic limbs to a new level, providing increased athletic performance, increased control, and reduced body strain. It is a further object of the present invention to provide essential elements needed for making prosthetic limbs that more accurately mimic the mechanical behavior of healthy human limbs.
Description of Normal, Level-Ground Walking:
[0004] In order to establish terminology used in this document, the basic walking progression from heel strike to toe off is first explained. There are three distinct phases to a walking stance-period as depicted in FIG. 1 with heel-toe sequence 1 through 7.
Saggital Plane Knee Phases
[0000]
1. Beginning with heel strike, the stance knee begins to flex slightly (Sequence 1-3). This flexion allows for shock absorption upon impact as well as keeping the body's center of gravity at a more constant vertical level throughout stance.
2. After maximum flexion is reached in the stance knee, the joint begins to extend again, until full extension is reached (Sequence 3-5).
3. During late stance, the knee of the supporting leg begins to flex again in preparation for the swing phase (Sequence 5-7). This is referred to in the literature as ‘knee break’. At this time, the adjacent foot strikes the ground and the body is in “double support mode” (that is to say, both legs are supporting body weight).
Saggital Plane Ankle Phases
[0000]
1. Beginning with heel strike, the ankle undergoes a controlled plantar-flexion phase where the foot rotates towards the ground until the forefoot makes contact (Sequence 1-2).
2. After controlled plantar-flexion, the ankle undergoes a controlled dorsi-flexion phase where the tibia rotates forwardly while the foot remains in contact with the ground (Sequence 2-5).
3. During late stance, the ankle undergoes a powered plantar-flexion phase where the forefoot presses against the ground raising the heel from the ground (Sequence 5-7). This final phase of walking delivers a maximal level of mechanical power to the walking step to slow the fall of the body prior to heel strike of the adjacent, forwardly positioned leg.
[0011] The development of artificial leg systems that exhibit natural knee and ankle movements has been a long standing goal for designers of legged robots, prostheses and orthoses. In recent years, significant progress has been made in this area. The current state-of-the-art in prosthetic knee technology, the Otto Bock C-Leg, enables amputees to walk with early stance knee flexion and extension, and the state-of-the-art in ankle-foot systems (such as the Össur Flex-Foot) allow for ankle controlled plantar-flexion and dorsi-flexion. Although these systems restore a high level of functionality to leg amputees, they nonetheless fail to restore normal levels of ankle powered plantar-flexion, a movement considered important not only for biological realism but also for walking economy. In FIG. 2 , ankle power data are shown for ten normal subjects walking at four walking speeds from slow (½ m/sec) to fast (1.8 m/sec). As walking speed increases, both positive mechanical work and peak mechanical power output increase dramatically. Many ankle-foot systems, most notably the Flex-Foot, employ springs that store and release energy during each walking step. Although some power plantar-flexion is possible with these elastic systems, normal biological levels are not possible. In addition to power limitations, the flex-foot also does not change stiffness in response to disturbances. The human ankle-foot system has been observed to change stiffness in response to forward speed variation and ground irregularities. In FIG. 3 , data are shown for a normal subject walking at three speeds, showing that as speed increases ankle stiffness during controlled plantar-flexion increases.
[0012] Artificial legs with a mechanical impedance that can be modeled as a spring in parallel with a damper are known in the art. Some prostheses with non-linear spring rates or variable damping rates are also known in the art. Unfortunately, any simple linear or non-linear spring action cannot adequately mimic a natural limb that puts out positive power during part of the gait cycle. A simple non-linear spring function is monotonic, and the force vs. displacement function is the same while loading the spring as while unloading the spring. It is an object of the present invention to provide actively electronically controlled prosthetic limbs which improve significantly on the performance of artificial legs known in the art, and which require minimal power from batteries and the like. It is a further object of the present invention to provide advanced electronically-controlled artificial legs which still function reasonably well should the active control function fail (for instance due to power to the electronics of the limb being lost). Still further, it is an object of the present invention to provide artificial legs capable of delivering power at places in the gait cycle where a normal biological ankle delivers power. And finally, it is an object of the present invention to provide prosthetic legs with a controlled mechanical impedance and the ability to deliver power, while minimizing the inertial moment of the limb about the point where it attaches to the residual biological limb.
[0013] During use, biological limbs can be modeled as a variable spring-rate spring in parallel with a variable damping-rate damper in parallel with a variable-power-output forcing function (as shown in FIG. 4 a ). In some activities, natural human limbs act mostly as spring-damper combinations. One example of such an activity is a slow walk. When walking slowly, a person's lower legs (foot and ankle system) act mostly as a system of springs and dampers. As walking speed increases, the energy-per-step put out by the muscles in the lower leg increases. This is supported by the data in FIG. 2 .
[0014] Muscle tissue can be controlled through nerve impulses to provide variable spring rate, variable damping rate, and variable forcing function. It is an objective of the present invention to better emulate the wide range of controllability of damping rate, spring rate, and forcing function provided by human muscles, and in some cases to provide combination of these functions which are outside the range of natural muscles.
SUMMARY OF THE INVENTION
[0015] There are two major classes of embodiments of the present invention. The first major class provides for actively controlled passive mechanical parameters (actively controlled spring rate and damping rate). This major class of embodiments will be referred to as variable-stiffness embodiments. Three sub-classes of variable-stiffness embodiments are disclosed:
1) Multiple parallel interlockable springs. 2) Variable mechanical advantage. 3) Pressure-variable pneumatics.
[0019] The second major class of embodiments of the present invention allows for the controlled storage and release of mechanical energy within a gait cycle according to any arbitrary function, including functions not available through simple nonlinear springs. Within this second major class of embodiments, energy can be stored and released at rates which are variable under active control. Thus for a given joint, the force vs. displacement function is not constrained to be monotonic or single-valued. Within this class of embodiments, energy (from either muscle or a separate on-board power source) can be stored and released along arbitrarily defined functions of joint angular or linear displacement, force, etc. This major subclass of embodiments shall be referred to herein as energy transfer embodiments. Two sub-classes of energy transfer embodiments are disclosed:
1) Bi-articular embodiments (which transfer energy from a proximal joint to a distal joint to mimic the presence of a missing joint). 2) Catapult embodiments (which store energy from a power source over one span of time and release it over another span of time to aid locomotion).
[0022] The present invention makes possible prostheses that have mechanical impedance components (damping and spring rate) and power output components that are actively controllable as functions of joint position, angular velocity, and phase of gait. When used in a prosthetic leg, the present invention makes possible control of mechanical parameters as a function of how fast the user is walking or running, and as a function of where within a particular step the prosthetic leg is operating.
[0023] It is often necessary to apply positive mechanical power in running shoes or in orthotic and prosthetic (O&P) leg joints to increase locomotory speed, to jump higher, or to produce a more natural walking or running gait. For example, when walking at moderate to high speeds, the ankle generates mechanical power to propel the lower leg upwards and forwards during swing phase initiation. In FIG. 2 , data are shown for ten normal subjects showing that the ankle delivers more energy during a single step than it absorbs, especially for moderate to fast walking speeds.
[0024] Two catapult embodiments of the present invention are described in which elastic strain energy is stored during a walking, running or jumping phase and later used to power joint movements. In a first embodiment, catapult systems are described in which storage and release of stored elastic energy occurs without delay. In a second embodiment, elastic strain energy is stored and held for some time period before release. In each Embodiment, mechanism architecture, sensing and control systems are described for shoe and O&P leg devices. Although just a few devices are described herein, it is to be understood that the principles could be used for a wide variety of applications within the fields of human-machine systems or legged robots. Examples of these first and second catapult embodiments are shown in FIGS. 4 through 6 .
[0025] One bi-articular embodiment of the invention described herein comprises a system of knee-ankle springs and clutches that afford a transfer of energy from hip muscle extensor work to artificial ankle work to power late stance plantar-flexion. Since the energy for ankle plantar-flexion originates from muscle activity about the hip, a motor and power supply need not be placed at the ankle, lowering the total mass of the knee-ankle prosthesis and consequently the metabolic cost associated with accelerating the legs in walking. Examples of these embodiments are shown in FIGS. 7 and 8 .
[0026] Several variable-stiffness embodiments are described herein in which variable spring-rate structures are constructed by varying the length of a moment arm which attaches to a spring element about a pivot axis, thus providing a variable rotational spring rate about the pivot axis. Examples of such embodiments are depicted in FIGS. 9 through 11 . In a preferred embodiment, variations in the length of the moment arm are made under microprocessor control at times of zero load, to minimize power consumed in the active control system.
[0027] Variable-stiffness embodiments of the present invention employing multiple interlockable parallel spring elements are depicted in FIGS. 12 through 14 . In FIGS. 12 a and 12 b , multiple parallel elastic leaf spring elements undergo paired interlocking at pre-set joint flexures or under microprocessor control. This embodiment makes possible arbitrary piecewise-linear approximations to non-linear spring functions (such as function 624 in FIG. 12 d ). A pneumatic embodiment which can be configured to behave similarly to the leaf spring embodiments shown in FIGS. 12 a and 12 b is shown in FIG. 13 . In the pneumatic embodiment of FIG. 13 , valves are electronically closed to effectively increase the number of pneumatic springs in parallel.
[0028] The multiple parallel spring elements in FIGS. 12 a , 12 b , and FIG. 13 could equivalently be replaced by other types of spring elements, such as coil springs, torsion bars, elastomeric blocks, etc.
BRIEF DESCRIPTION OF THE FIGURES
[0029] FIG. 1 : Depiction of stages of a gait cycle, including controlled plantar-flexion, controlled dorsi-flexion, and powered plantar-flexion.
[0030] FIG. 2 : Data from ten normal subjects are plotted showing mechanical power output versus percent gait cycle in walking. Both zero and one hundred percent gait cycle correspond to heel strike of the same foot
[0031] FIG. 3 : Data for one subject, showing normal biological ankle function during the controlled plantar-flexion phase of walking.
[0032] FIG. 4 a : Basic catapult embodiment of the present invention, represented in terms of a lumped-parameter model.
[0033] FIG. 4 b : Force-displacement graph where darkened area represents extra stored energy (used in walking/running) put into catapult system by force actuator while prosthetic foot is off the ground.
[0034] FIG. 4 c : Side view of simplified prosthetic mechanism designed to provide powered plantar-flexion.
[0035] FIG. 4 d : Front view of simplified prosthetic mechanism designed to provide powered plantar-flexion.
[0036] FIG. 5 a : Catapult foot prosthesis or shoe orthosis for walking, running, and jumping, shown in the equilibrium configuration.
[0037] FIG. 5 b : Catapult foot prosthesis or shoe orthosis for walking, running, and jumping, shown in a compressed state.
[0038] FIG. 6 a : Side view of catapult leg prosthesis for walking, running, and jumping, shown in the equilibrium state.
[0039] FIG. 6 b : Side view of catapult leg prosthesis for walking, running, and jumping, shown in a compressed state.
[0040] FIG. 6 c : Front view of catapult leg prosthesis for walking, running, and jumping.
[0041] FIG. 7 : An external, bi-articular transfemoral prosthesis or orthosis is shown in a heel strike to toe-off walking sequence. The system comprises springs and controllable clutches to transfer energy from hip muscular work to ankle powered plantar-flexion work.
[0042] FIG. 8 : An external, bi-articular transfemoral prosthesis or orthosis Is shown in a heel strike to toe-off walking sequence. The system comprises pneumatic springs and controllable valves to transfer energy from hip muscular work to ankle powered plantar-flexion work.
[0043] FIG. 9 : Perpendicularly-variable-moment pivotal spring structure.
[0044] FIG. 10 : Mechanical diagram of a low-profile prosthetic foot where spring elements are actively controlled (positioned) to affect ankle joint stiffness.
[0045] FIG. 11 : Variable-stiffness joint according to the present invention, utilizing variable mechanical advantage to produce variable spring rate and/or variable damping rate.
[0046] FIG. 12 a : Multiply interlockable parallel leaf spring structure, shown in equilibrium position.
[0047] FIG. 12 b : Multiply interlockable parallel leaf spring structure, shown in a stored-energy position.
[0048] FIG. 12 c : End view of two dove-tailed slidably attached leaf spring terminations with controllable interlock actuator.
[0049] FIG. 12 d : Piecewise-linear approximation to nonlinear spring function achieved by interlocking successive parallel leaf springs at various angles, and smoothed nonlinear spring function achieved by interlocking successive parallel leaf springs through coupling springs.
[0050] FIG. 12 e : Nonlinear damping element coupling mechanism for coupling multiple spring elements.
[0051] FIG. 13 : Multiple-pneumatic-chamber variable spring rate and energy transfer system.
[0052] FIG. 14 : Prosthetic ankle/foot utilizing multiple interlockable parallel leaf springs for ankle spring.
[0053] FIG. 15 : Example prosthetic ankle/foot known in the art.
[0054] FIG. 16 : Variable-stiffness pneumatic spring.
DETAILED DESCRIPTION
[0055] A powered-catapult embodiment of the present invention is shown in FIGS. 4 a - 4 d . FIG. 4 a is a lumped-element model of a powered-catapult prosthetic. The mounted end 203 of the prosthesis attaches to the body, and the distal end 204 of the prosthesis interfaces to the environment (such as the ground for a leg prosthesis). Mounted end 203 is coupled to distal end 204 through spring 202 , and through the series combination of force actuator 205 and force sensor 201 . In some embodiments, displacement sensor 206 may also be included in parallel with spring 202 . If the system is designed to operate in parallel with an existing limb, the muscles of the existing limb are modeled by muscle 200 .
[0056] A mechanical implementation of lumped-element diagram 4 a is shown in side view in FIG. 4 c and in front view in FIG. 4 d . In a preferred embodiment, during the portion of a gait cycle when the foot is not in contact with the ground, motor 205 turns spool 209 to wind on some of tension band 208 , storing energy in spring 202 . Force sensor 201 and winding distance sensor 207 may be used in a control loop to control how much energy is stored in spring 202 , and how rapidly this energy is stored. Once the desired energy has been stored, clutch 207 is actuated to keep tension band 208 from unwinding and spring 202 from relaxing until the control system decides to release the stored energy. The energy stored in spring 202 during the swing phase of the gait cycle is represented by the dark area on the force vs. distance graph shown in FIG. 4 b.
[0057] During the powered plantar-flexion phase of the gait cycle, the control system releases clutch 207 , allowing the stored energy in spring 202 to be released, imitating the powered plantar-flexion stage of a normal gait cycle. This release of energy mimics the pulse of power put out by a biological ankle during the powered plantar-flexion stage of a walking or running gait cycle.
[0058] In an alternate embodiment, motor 205 may store energy in spring 202 at the same time as the natural leg stores impact energy during the gait cycle. This embodiment can be used to effectively implement one spring rate during compression (such as the spring rate depicted by the line from the origin to point Kd in FIG. 4 b ) and another spring rate during release (such as the spring rate depicted by the line from the origin to point Ks in FIG. 4 b ).
[0059] In an alternate embodiment, FIG. 5 shows a prosthetic foot or shoe orthosis that stores both muscle energy and motor energy in spring mechanism 300 during the gait cycle, for release during the powered plantar-flexion stage of the walking gait cycle (toe-off propulsion). When walking on this type of catapult prosthesis or foot orthosis, a person would experience a first (lower) spring rate (depicted by the line from the origin to point Kd in FIG. 4 b ), and a second (higher) spring rate (depicted by the line from the origin to point Ks in FIG. 4 b ) when releasing energy from spring 300 during the powered plantar-flexion phase of the gait cycle.
[0060] For catapult embodiments depicted in both FIG. 4 and in FIG. 5 , part of the energy released during powered plantar-flexion came from leg muscle action compressing springs 202 and 300 , and part came from an electromechanical actuator such as a motor. In a preferred embodiment of the present invention as depicted in FIG. 4 , the majority of power stored in spring mechanisms by electromechanical actuators occurs during the minimal-load portion of the walking/running gait cycle (swing phase), and the start of the energy-release phase (late stance phase) of the gait cycle may be time-delayed with respect to the swing phase when motor energy is stored.
[0061] FIG. 6 is another depiction of the catapult leg prosthesis of FIG. 4 , also showing socket 400 , which attaches to the residual biological limb. Although the leg prostheses shown in FIGS. 4 and 6 are below-the-knee prostheses, the invention could also be employed in above-knee prostheses.
[0062] Two bi-articular embodiments of the present invention are shown in FIGS. 7 and 8 . In a first embodiment ( FIG. 7 ), a prosthesis (above or below knee), robotic leg or full leg orthosis is shown having above-knee segment (a), knee joint (b), ankle joint (c), posterior knee pivot (d), posterior clutch (e), posterior spring (f), posterior cord (g), knee-ankle transfer clutch (h), anterior pivot (i), anterior clutch (j), anterior spring (k), and anterior cord (l). Anterior spring (k) stretches and stores energy during early stance knee flexion (from 1 to 3) and then releases that energy during early stance knee extension (from 3 to 5). Here spring (k) exerts zero force when the knee is fully extended, and anterior clutch (j) is engaged or locked throughout early stance knee flexion and extension (from 1 to 5). This stored energy, together with an applied extensor hip moment from either a robotic or biological hip, result in an extensor moment at the knee, forcing the knee to extend and stretching posterior spring (f) (from 3 to 5). The spring equilibrium length of posterior spring (f) is equal to the minimum distance from posterior knee pivot (d) to posterior clutch (e) (leg configuration 3 in FIG. 7 ). To achieve this spring equilibrium, posterior clutch (e) retracts posterior cord (g) as the distance from posterior knee pivot (d) to posterior clutch (e) becomes smaller. When this distance begins to increase in response to knee extension and ankle dorsi-flexion (from 4 to 5), posterior clutch (e) engages, causing posterior spring (f) to stretch. When the ankle is maximally dorsi-flexed and the knee fully extended (leg configuration 5 ), posterior spring (f) becomes maximally stretched. When the leg assumes this posture, knee-ankle transfer clutch changes from a disengaged state to an engaged state. Engaging the knee-ankle clutch mechanically grounds spring (f) below the knee rotational axis, and consequently, all the energy stored in spring (f) is transferred through the ankle to power ankle plantar-flexion (from 6 to 7). During late stance (from 5 to 6), the knee of the supporting leg begins to flex again in preparation for the swing phase. For this late stance knee flexion, anterior clutch (j) is disengaged to allow the knee to freely flex without stretching anterior spring (k).
[0063] It should be understood that the bi-articular knee-ankle invention of embodiment I ( FIG. 7 ) could assume many variations as would be obvious to those of ordinary skill in the art. For example, the system described herein could act in parallel to additional ankle-foot springs and/or to an active or passive knee damper. Additionally, instead of mechanically grounding spring (f) distal to the knee axis to effectively transfer all the stored energy through the ankle, the perpendicular distance from the line of spring force (f) to the knee's axis of rotation could go to zero as the knee approaches full extension.
[0064] In a second embodiment ( FIG. 8 ), a prosthesis (above or below knee), robotic leg or full leg orthosis is shown having a similar energy transfer from hip muscle extensors to artificial leg to power ankle plantar-flexion, accept energies are stored within pneumatic springs about the knee and then transferred to the ankle via a fluid transfer system. In this embodiment, the transfer of energy occurs without a physical bi-articular spring such as posterior spring (f) in FIG. 7 . In this embodiment, anterior pneumatic spring (j) compresses and stores energy during early stance knee flexion (from 1 to 3). Here anterior knee valve (k) is closed or locked throughout early stance knee flexion and extension (from 1 to 5). This stored energy, together with an applied extensor hip moment from either a robotic or biological hip, result in an extensor moment at the knee, forcing the knee to extend and compress posterior pneumatic spring (f) (from 3 to 5). It is important to note that posterior knee valve (g) is open during early stance knee flexion so that posterior pneumatic spring (f) exerts little force. Knee valve (g) is then closed during knee extension so that energy is stored in the posterior pneumatic spring (f). When the ankle is maximally dorsi-flexed and the knee fully extended (leg configuration 5 ), posterior pneumatic spring (f) is maximally compressed. When the leg assumes this posture, knee-ankle transfer valve changes from a closed state to an open state, and anterior ankle valve (n) changes to a closed state, allowing all the energy stored in spring (f) is be transferred through the ankle to power ankle plantar-flexion (from 6 to 7). During late stance (from 5 to 6), the knee of the supporting leg begins to flex again in preparation for the swing phase. For this late stance knee flexion, anterior and posterior valves (g, k) are open to allow the knee to freely flex without compressing anterior spring (j).
[0065] It should be understood that the bi-articular knee-ankle invention of embodiment II ( FIG. 8 ) could assume many variations as would be obvious to those of ordinary skill in the art. For example, the system described herein could act in parallel to active or passive ankle-foot springs and/or to an active or passive knee damper. Additionally, the energy in posterior pneumatic spring (f) could be transferred to a temporary holding chamber to be later released to the ankle during powered plantar-flexion.
[0066] The mechanical system in FIG. 9 is a variable-mechanical-advantage embodiment of a variable-stiffness spring. Motors 500 and motor-driven screws 505 serve to change the moment of compression of bow spring 503 about pivot point 504 . This mechanism may be used to adjust spring stiffness with minimal power under no-load conditions. It may also be used as an alternative way of storing energy in a spring which is under load, and thus may be used as a component of an immediate-release catapult system such as depicted in FIG. 5 .
[0067] FIG. 10 depicts a low-profile prosthetic foot-ankle with top plate 1 and bottom plate 2 , where spring elements are actively controlled (positioned) to affect ankle joint stiffness. This embodiment of the present invention is a variable-stiffness embodiment of the “variable mechanical advantage” sub-class. In this low-profile prosthetic ankle joint embodiment, side-to-side spring rates of the prosthetic ankle and front-to-back spring rates of the prosthetic ankle are adjusted by varying the distance of spring elements 4 , 5 , 6 , and 7 from the central pivot point 15 of the ankle joint. Spring top plates 13 and spring bottom plates 12 of spring elements 4 , 5 , 6 , and 7 slide in tracks 14 , driven by position-adjusting motors 8 , 9 , 10 , and 11 . In a preferred embodiment, motors 8 , 9 , 10 , and 11 only change the positions of spring elements 4 , 5 , 6 , and 7 when the ankle joint is under zero load (for instance, during the part of the walking gait when the foot is not in contact with the ground). Adjustment of spring position under zero load allows position adjustments to be done with minimal energy. This embodiment offers independent inversion/eversion stiffness control as well as independent plantar-flexion and dorsi-flexion control.
[0068] A variable stiffness ankle-foot prosthesis embodiment according to the present invention is shown in FIG. 11 . Constant-rate spring or damping element 1700 fixedly attached at one end and movably attached at the other end. Attachment point 1701 may be moved in and out with respect to the effective pivot point of the ankle joint. If element 1700 is a damping element, this configuration provides a variable damping ankle joint. If element 1700 is a spring element, this configuration provides a variable spring rate ankle joint. FIGS. 9 , 10 and 11 demonstrate how a constant element can be transformed into a variable element according to the present invention, by varying mechanical advantage. In non-catapult preferred embodiments of the present invention, the variation in mechanical advantage takes place such that the motion used to vary the mechanical advantage takes place substantially perpendicular to the force the element being moved is under, thus minimizing the work needed to vary the mechanical advantage.
[0069] FIGS. 12 a and 12 b depict a multiple-parallel-leaf-spring embodiment of a variable mechanical impedance according to the present invention. Leaf springs 600 are bound together and bound tightly to attaching bracket 602 at one end by bolt 801 . At the other end, leaf springs terminate in slidably interlocking blocks 603 , which may be locked together dynamically in pairs by interlocking plates 605 . Each interlocking plate 605 is permanently bonded to one leaf spring terminator block 603 at surface interface 606 , and controllably bindable to a second leaf spring terminator block 604 at a second interface 607 , by binding actuator 608 . Binding actuator 608 may bind surface interface 607 by any number of means such as mechanical clamp, pin-in-socket, magnetic clamp, etc. Adjacent leaf spring terminator blocks are slidably attached by dovetail slides or the like. The structure shown in FIGS. 12 a - c can be used to implement a piecewise-linear spring function such as function 604 depicted in FIG. 12 d , by engaging successive interlocks 605 at pre-determined points in spring flexure, and disengaging at like points.
[0070] In a preferred embodiment, the slope discontinuities in function 604 may be “smoothed” by coupling successive leaf springs through coupling springs. In FIG. 12 d , stop plate 619 is affixed to leaf spring termination 620 , and coupling spring 621 is mounted to leaf spring termination 618 through coupling spring mount 622 . Leaf spring termination 620 is free to slide with respect to leaf spring termination 618 until coupling spring 621 and stop plate 619 come in contact. Coupling spring 621 acts to smooth the transition from the uncoupled stiffness of two leaf springs to the coupled stiffness of two leaf springs, resulting in smoothed force-displacement function 625 in FIG. 12 d.
[0071] In a preferred embodiment, coupling spring 621 is itself a stiff, nonlinear spring. In another preferred embodiment, coupling spring 621 may have actively controllable stiffness, and may be made according to any of variable-stiffness spring embodiments of the present invention.
[0072] FIG. 12 e depicts a non-linear dissipative coupling mechanism for coupling pairs of spring elements in a multiple-parallel-element spring. Mechanical mounts 609 and 610 affix to a pair of spring elements to be coupled. In a preferred embodiment, one of 609 and 610 is permanently affixed and the other of 609 and 610 is controllably affixed through a mechanism such as 608 described above. Piston 611 is coupled to mount 609 through rod 612 which passes through seal 614 . Thus piston 611 may move back and forth in chamber 615 along the axis of rod 612 . Chamber 615 is preferably filled with viscose or thixotropic substance 616 . A viscose substance can be used in chamber 616 to provide a mechanical coupling force proportional to the square of the differential velocity between mounts 609 and 610 . A thixotropic substance (such as a mixture of corn starch and water) can be used to provide an even more nonlinear relationship between coupling force and the differential velocity between coupling plates 609 and 610 . Alternately, an electronically controlled variable damping element may be used in series with force sensor 617 between mounts 609 and 610 , to provide an arbitrary non-linear dissipative coupling.
[0073] Utilizing a nonlinear dissipative coupling between pairs of elements in a multiple-parallel-element spring allows joint spring rates in a prosthetic limb which are a function of velocity. Thus, a joint spring rate can automatically become stiffer when running than it is while walking.
[0074] In one preferred embodiment, chamber 615 is rigidly mounted to mount 610 . In another preferred embodiment, chamber 615 is mounted to mount 610 through coupling spring 623 . In a preferred embodiment, coupling spring 623 may be an actively-controlled variable stiffness spring according to the present invention.
[0075] FIG. 13 depicts a multiple-couplable-parallel element pneumatic embodiment of the present invention. Multiple parallel pneumatic chambers 900 couple mounting plates 908 and 909 . Pneumatic hoses 902 connect chambers 900 to a common chamber 901 through individually actuatable valves 903 . Spring stiffness between plates 908 and 909 is maximized when all valves 903 are closed, and minimized when all valves 903 are open. Additional pneumatic element 905 may be added to transfer power from one prosthetic joint to another.
[0076] In an immediate-energy-transfer embodiment of the present invention according to FIG. 13 , valves 904 and 906 may be timed to actuate in sequence with valves 903 to transfer power directly from chamber 905 to chambers 900 . In a delayed-energy-transfer embodiment of the present invention according to FIG. 13 , energy may be transferred from chamber 905 to chambers 900 or vice versa in a delayed manner, by chambers 900 or chamber 905 first pressurizing chamber 901 , then isolating chamber 901 by closing valves 903 and 904 for some period of time, then transferring the energy stored in chamber 901 to chambers 900 or 905 by opening the appropriate valves.
[0077] FIG. 15 a depicts a prosthetic ankle-foot system known in the art. Ankle spring 1500 is affixed to foot-plate 1501 . One variable-stiffness embodiment of the present invention shown in FIG. 15 uses a multiple-parallelly-interlockable-leaf-spring structure such as that shown in FIG. 12 in place of ankle spring 1500 . Multiple-parallelly-interlockable-leaf-spring 1600 allows for different spring rates in forward and backward bending, allowing separately controllable rates of controlled plantar-flexion and controlled dorsi-flexion.
[0078] In one embodiment of the present invention (shown in FIG. 15 b ), ankle spring 1500 is split into inner ankle spring 1500 a , and outer ankle spring 1500 b , and heel spring 1501 is split rearward of attachment point AP into inner heel spring 1501 a and outer heel spring 1501 b . In a preferred embodiment, ankle springs 1500 a and 1500 b and heel springs 1501 a and 1501 b each comprise actively-variable multi-leaf springs such as ankle spring 1600 in FIG. 14 . Having separate inner and outer variable-stiffness ankle springs allows for active control of side-to-side stiffness of the prosthetic ankle joint. Having separate inner and outer variable-stiffness heel springs allows for active control medio-lateral ankle stiffness.
[0079] A pneumatic embodiment of a variable-stiffness spring for a prosthesis is shown in FIG. 16 . Male segment 702 comprises one end of the overall variable-stiffness spring, and female segment 701 comprises the other end. Control electronics 710 are contained in the upper end of male segment 710 . Intake valve 715 is actuatable to allow air to enter pressure chamber 708 through air intake channel 716 when pressure chamber 708 is below atmospheric pressure (or an external pump may be used to allow air to enter even when chamber 708 is above atmospheric pressure). Air pressure sensor 709 senses the pressure in pressure chamber 708 . Pressure chamber 708 is coupled to second pressure chamber 703 through valve 711 . The air in pressure chamber 703 acts as a pneumatic spring in parallel with spring 704 . Motor 705 turns ball screw 707 to move piston 706 back and forth to control the volume of pressure chamber 708 . Pressure in pressure chamber 703 may be lowered to a desired value by opening valve 703 for a controlled period of time, allowing air to escape through pressure release channel 714 .
[0080] In one mode of operation, valve 711 is open and pressure chambers 708 and 703 combine to form a single pressure chamber. In this mode, movement of piston 706 directly controls the overall pressure chamber volume, and thus the overall pneumatic spring rate. In another mode of operation, valve 711 is closed, and valve 706 may be opened and piston 706 may withdrawn to add air to the system.
[0081] In a preferred embodiment of a variable-stiffness leg prosthesis according to the present invention is implemented through the pneumatic system of FIG. 16 , motion of piston 706 occurs under minimal load, such as during the phase of gait when the foot is off the ground, or when the user is standing still.
[0082] The pneumatic system shown in FIG. 16 may also be used to implement Immediate-release or delayed-release catapult embodiments of the present invention. An immediate-release catapult may be implemented by opening valve 711 , and using motor 705 to add power (for instance, during the powered plantar-flexion phase of gait) as the power is needed. In a delayed-release catapult embodiment of the present invention, valves 715 and 711 are closed while motor 705 moves piston 706 to pressurize chamber 708 , and then energy stored in chamber 708 is rapidly released during a phase of gait to produce the same effect as powered plantar-flexion.
[0083] In a preferred embodiment of the present invention, a pneumatic prosthetic leg element according to FIG. 16 is combined with the multiple controllably-couplable parallel leaf spring prosthetic ankle-foot of FIG. 15 to provide a prosthetic limb which provides powered plantar-flexion, controllable compressional leg spring stiffness, and controllable ankle stiffness during controlled plantar-flexion and controlled dorsi-flexion.
[0084] The foregoing discussion should be understood as illustrative and should not be considered to be limiting in any sense. 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 spirit and scope of the invention as defined by the claims.
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In one aspect, the invention provides methods and apparatus facilitating an adjustable-stiffness prosthesis or orthosis (including approximations to arbitrarily definable non-linear spring functions). Spring rates may be varied under no-load conditions during a walking gate cycle to minimize power consumption. In another aspect, the invention provides methods and apparatus for outputting positive power from a prosthesis or orthosis, facilitating high-performance artificial limbs. In one embodiment of the invention, the positive power is transferred from a functioning muscle to the prosthesis or orthosis, which mimics or assists a non-functioning or impaired muscle. In another embodiment of the invention, the positive power comes from an on-board power source in the prosthesis or orthosis.
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BACKGROUND
The present invention relates generally to integrated circuits, and more particularly, to an improved design of a dual-voltage three-state buffer circuit using a tri-state level shifter.
A conventional dual-voltage three-state buffer includes two level shifters to control a post driver circuit that is made of PMOS and NMOS transistors. The two level shifters translate lower voltage signals to higher voltage signals. The post driver circuit determines the output of the overall circuit by deciding which transistor is to be turned on or off. However, the time it takes for the PMOS and NMOS transistors to turn on or off is different, since PMOS transistors are usually slower to drive than NMOS transistors. The time required for a signal to output from each of the level shifters may also be different, since different input signals can create different paths for the signals to travel through, wherein some paths may take more time than the others. With all these timing differences, a cross-bar current can occur during the switching of the transistors in the post driver circuit, thereby degrading the performance for the circuit. In order for a conventional dual-voltage three-state buffer to solve such issues, unbalanced inverters are inserted between the level shifter outputs and the transistors of the post driver circuit. While this method reduces the cross-bar current of the post driver circuit, the inverters are extremely unbalanced, consume extra power, and require additional layout areas.
Desirable in the art of dual-voltage buffer designs are designs that provide less power consumption, smaller layout area, and better versatility.
SUMMARY
In view of the foregoing, this invention provides an improved design of a dual-voltage buffer circuit by implementing tri-state level shifter. In one embodiment, it has a tri-state logic control module operated under a low supply voltage, a level shifter for receiving one or more inputs from the tri-state logic control module and operating with an output control circuit for controlling two differential outputs of the level shifter, and a post driver circuit having a PMOS transistor and an NMOS transistor connected in series and driven by the two differential outputs of the level shifter, wherein the level shifter, the output control circuit, an the post driver circuit are operated under a high supply voltage, and wherein when the tri-state logic control module generates the inputs for putting the post driver circuit in a high impedance state, the output control circuit operates with the level shifter to turn off the PMOS and NMOS transistors of the post driver circuit while isolating the level shifter from a high supply voltage.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following descriptions of specific embodiments when read in connection with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates a conventional dual-voltage three-state buffer circuit comprised of a decoder with two level shifters.
FIG. 1B presents a truth table of the conventional dual-voltage three-state buffer circuit.
FIG. 2A illustrates a dual-voltage three-state buffer circuit in accordance with a first embodiment of the present invention.
FIG. 2B presents a truth table of the dual-voltage three-state buffer circuit in accordance with the first embodiment of the present invention.
FIG. 3A illustrates a dual-voltage three-state buffer circuit in accordance with a second embodiment of the present invention.
FIG. 3B presents a truth table of the dual-voltage three-state buffer circuit in accordance with the second embodiment of the present invention.
FIG. 4 presents a diagram illustrating the relationship of various signals in accordance with the first embodiment of the present invention.
DESCRIPTION
The present invention provides a dual-voltage three-state buffer circuit with a tri-state level shifter that simplifies circuit design. As such, the invention reduces the layout area and power consumption by the dual-voltage circuit.
FIG. 1A illustrates a conventional dual-voltage three-state buffer 100 comprised of a decoder with level shifters 102 and 104 . The buffer 100 has two modes of operation: normal mode and tri-state mode. These modes of operation are controlled by an enable pin 106 and an input pin 108 . The normal mode allows the buffer 100 to output what is inputted from the input pin 108 to a pad 110 , if the enable pin 106 is set low. Tri-state mode's function is to turn off a post driver PMOS transistor 112 and a post driver NMOS transistor 114 to create high impedance at the output of the buffer 100 .
For this example, the enable pin 106 is expected to be low and the input pin 108 is expected to be high to illustrate the operation of the normal mode of the buffer 100 . A control logic block 116 in the buffer 100 is powered by a low voltage source VDD and is made up of an AND gate 118 , an OR gate 120 , and three inverters 122 , 124 and 126 . The components within the control logic block 116 work together to provide the correct input signal for the level shifters 102 and 104 . The OR gate 120 takes in the high signal from the input pin 108 and the low signal from the enable pin 106 to provide a high signal for a node 128 . The AND gate 118 takes in the high signal from the input pin 108 and the high inverted enable signal from the inverter 122 to provide a node 130 with a high signal. The high signals from the nodes 128 and 130 then turn on NMOS transistors 134 and 132 , while the low signals at the gates of NMOS transistors 136 and 138 caused by the inverters 124 and 126 turn off the NMOS transistors 136 and 138 . With both NMOS transistors 132 and 134 turned on, nodes 140 and 142 are both pulled to low, and in return provide the gates of PMOS transistors 144 and 146 with low signals. The PMOS transistors 144 and 146 will turn on and pull the nodes 148 and 150 high due to the source voltage VDDIO. The high signal at the nodes 148 and 150 will turn off the PMOS transistors 152 and 154 and also be inverted to low signals before reaching the post driver transistors 112 and 114 by going through inverters 156 and 158 . The low signals at the gates of the transistors will turn the transistor 112 on and the transistor 114 off. This allows a node 160 to be pulled high by source voltage VDDIO, thereby giving a high output signal at the pad 110 .
To show how the circuit 100 operates during tri-state mode, both the enable pin 106 and the input pin 108 are now set to high. The two signals will first go through the control logic block 116 . In the control logic block 116 , the AND gate 118 takes in a low inverted enable signal from the inverter 122 and a high signal from the input pin 108 to give the node 130 a low signal. Similarly, the OR gate 120 takes in a high signal from the input pin 108 and the enable pin 106 to provide the node 128 with a high signal. The low signal at the node 130 will turn the NMOS transistor 132 off and the NMOS transistor 136 on after going through the inverter 124 . The high signal at the node 128 turns the NMOS transistor 134 on and the NMOS transistor 138 off after going through the inverter 126 . As a result, nodes 148 and 142 are pulled to low, thereby turning the PMOS transistors 152 and 146 on. The nodes 140 and 150 are pulled high by the source voltage VDDIO since the PMOS transistors 152 and 146 are turned on. The two high state nodes 140 and 150 help turn off the PMOS transistors 144 and 154 . With the node 148 pulled to low and the node 150 pulled to high, both signals are inverted after going through the inverters 156 and 158 . The output of the inverter 156 provides the gate of the transistor 112 with a high signal, thereby turning the transistor 112 off. The inverter 158 outputs a low signal for the gate of the transistor 114 , thereby turning the transistor 114 off. With both transistors 112 and 114 turned off, the circuit enters tri-state, and both the node 160 and the PAD 110 will have high impedance.
FIG. 1B presents a truth table 162 of the conventional dual-voltage three-state buffer 100 . The truth table 162 shows the expected output signals for all three possible states with different combinations of enable or input signals.
While the buffer 100 reduces post driver cross-bar current and translates lower voltage to higher voltage with the use of two level shifters 102 and 104 , the inverter ratio that drives the gates of post driver transistors 112 and 114 are extremely un-balanced because of the timing issues. Furthermore, the level shifters 102 , 104 and inverters 156 , 158 increase the power consumption and layout area. This invites an improved design of the dual-voltage three-state buffer.
FIG. 2A illustrates a dual-voltage three-state buffer circuit 200 in accordance with the first embodiment of the present invention. The circuit 200 includes only one level shifter and a plurality of pull-up and pull-down switches.
Like the buffer 100 , the circuit 200 also switches between three different states with two modes of operation: normal mode and tri-state mode. Normal mode occurs when an enable pin 202 is set to low, and allows a PAD 204 to output the inverse signal of what was inputted into an input pin 206 . In order to activate the tri-state mode, the enable pin 202 will be set to high by an output enable signal. Regardless of the state of the input signal, the PAD 204 will have a high impedance. The circuit 200 essentially serves to translate lower voltage signals to higher voltage signals with the help of a tri-state level shifter. Only a tri-state logic control module 208 and other components before it are supplied by a lower voltage source VDD. All other components within the circuit 200 are powered by a higher voltage power supply VDDIO.
A three state level shifter, which is collectively represented by PMOS transistors 232 , 238 and NMOS transistors 218 , 220 , is connected between a high voltage output switch such as a PMOS transistor 234 and ground. A high voltage output control circuit, which may include the PMOS transistor 234 , 240 , 246 , and NMOS transistor 222 are powered by the high voltage power supply. The NMOS transistor 222 is connected to the gate of the PMOS transistor 234 on one end and the ground on the other with its gate controlled by node 224 . The level shifter is connected to a post driver circuit, which includes a PMOS transistor 242 and a NMOS transistor 250 , via an inverter 244 and a buffer 248 . The gate of the PMOS transistor 240 is further connected to the inverter 244 , and the gate of the PMOS transistor 246 is further connected to the buffer 248 . It is noted that the transistor 240 and 246 are connected in series, with the gate of the transistor 240 connected to the input of the inverter 244 , and with the gate of the transistor 246 tied to the input of the buffer 248 . As such, the high voltage output control circuit affects how signals travel from the differential outputs, i.e., nodes 228 and 236 , of the level shifter to the post driver circuit.
To illustrate how normal mode operates, a low signal is inputted into the enable pin 202 and a high signal is inputted into the input pin 206 . The two signals first go through the tri-state logic control module 208 that is powered by a low voltage source VDD. The tri-state logic control module 208 is made of several logic components: inverters 210 and 212 , and NAND gates 214 and 216 . These components work together to determine which of the pull-down transistors 218 , 220 , and 222 are to be turned on or turned off. A node 224 simply has a high inverted signal of what is inputted to the enable pin 202 . This high signal at the node 224 will turn on the transistor 222 . A node 226 controls the switching of the transistor 218 and it has a high signal since the NAND gate 214 takes in the high signal from the node 224 and the low inverted signal of the input pin 206 from the inverter 210 . The high signal of the node 226 also turns on the transistor 218 . With both signals at the nodes 224 and 226 high, the NAND gate 216 provides the gate of the transistor 220 with a low signal, thereby turning it off. Since the transistors 218 and 222 are both turned on, the two differential output nodes 228 and 230 are both pulled low, thereby turning on the PMOS transistor 232 and a pull-up PMOS transistor 234 . This provides a straight path from source voltage VDDIO to a node 236 , thereby pulling it high. This in return also turns off the PMOS transistor 238 . With the node 228 pulled down, the PMOS transistor 240 is turned on. Since the gate of the post driver PMOS transistor 242 will have a high signal because of the inverter 244 , the transistor 242 will be turned off. The high signal at the node 236 turns off the PMOS transistor 246 and continues through a buffer 248 to turn on the post driver NMOS transistor 250 . Since the transistor 242 is turned off and the transistor 250 is turned on, the signal at the PAD 204 will be pulled low, which is the inverse of the input at the input pin 206 .
The tri-state mode can be activated by a high output enable signal at the enable pin 202 , thereby creating a high impedance to the output at the PAD 204 , regardless of the input signal at the input pin 206 . To show how the tri-state mode operates, both the enable pin 202 and the input pin 206 will be set to high. The operation begins by having the two signals enter the tri-state logic control block 208 to determine which of the pull-down switches are to be turned on or off. Because of the inverter 212 , the node 224 will have a low signal, which turns the transistor 222 off. The NAND gate 214 provides the node 226 with a high signal, after taking in the two low signals from the inverters 210 and 212 . The node 226 with a high signal turns on the transistor 218 . The NAND gate 216 takes in the high signal at the node 226 and the low signal at the node 224 , thereby providing a high signal to the gate of the transistor 220 and turning the transistor 220 on. This immediately pulls both the nodes 228 and 236 low and then turning the transistors 240 and 246 on. The gate of the switch/PMOS transistor 234 will be pulled high from the direct path connected to source voltage VDDIO. This helps to shut off high voltage power from the entire level shifter. The transistor 242 is turned off, after the low signal at the node 228 goes through the inverter 244 . The transistor 250 will also turn off since the low signal from the node 236 continues through the buffer 248 . With both transistors 242 and 250 turned off, the PAD 204 will have a very high impedance.
FIG. 2B presents a truth table 252 in accordance with the first embodiment of the present invention. The truth table 252 shows the expected output signals for all three possible states with different combinations of enable or input signals.
FIG. 3A illustrates a dual-voltage three-state buffer circuit 300 in accordance with the second embodiment of the present invention. The buffer circuit 300 has only one level shifter and several pull-up and pull-down switches.
Similar to the buffer 200 , the buffer 300 also switches between three different states with two modes of operation: normal mode and tri-state mode. Normal mode occurs when an enable pin 302 is set to low and it allows a PAD 304 to output the inverse signal of what is inputted into an input pin 306 . In order to activate the tri-state mode, the enable pin 302 will be set to high by an output enable signal. Regardless of the state of the input signal, the PAD 304 will have a high impedance. The dual-voltage three-state buffer circuit 300 also provides a function to translate lower voltage signals to higher voltage signals with the help of the tri-state level shifter. Only a tri-state logic control module 308 and other components before it are supplied by a lower source voltage VDD. All other components within the buffer 300 are powered by a higher source voltage VDDIO.
PMOS transistors 336 , 338 , collectively representing a high voltage output switch, are connected in parallel between a high voltage power supply and a level shifter. The level shifter, which is collectively represented by PMOS transistors 332 , 342 and NMOS transistors 318 , 322 , is connected between the PMOS transistors 336 , 338 and ground. An output control circuit, which is collectively represented by PMOS transistors 334 , 330 , NMOS transistor 320 , and output switches such as the PMOS transistors 336 , 338 , asserts controls over the differential outputs 328 and 340 of the level shifter. The NMOS transistor 320 is connected to the gate of the PMOS transistors 336 , 338 . The level shifter is connected to a post driver circuit, which includes a PMOS transistor 346 and a NMOS transistor 350 , via an inverter 348 and a buffer 352 , respectively. The gate of the PMOS transistor 340 is further connected to the inverter 348 , and the gate of the PMOS transistor 344 is further connected to the buffer 352 .
To illustrate how the normal mode of the buffer 300 operates, the enable pin 302 is set to low and the input pin 306 is set to high. The signals first arrive at the tri-state logic control block 308 . The tri-state logic control block 308 has the same function as the tri-state logic control block 208 used in the first embodiment as illustrated in FIG. 2A . The inverters 310 and 312 , and the NAND gates 314 and 316 works together in the tri-state logic control block 308 to provide commands for pull-down switches NMOS transistors 318 , 320 and 322 . The low signal at the enable pin 302 is inverted by the inverter 312 , thereby giving a node 324 a high signal, which then turns on the transistor 320 . The NAND gate 314 takes in the high signal at the node 324 and the low inverted input signal from the inverter 310 to provide a node 326 with a high signal. This in return also turns on the transistor 318 . The NAND gate 316 takes in the two high signals from the nodes 326 and 324 to give the gate of the transistor 322 a low signal, thereby turning it off. With both the transistors 318 and 320 switched on, nodes 328 and 330 are both pulled to low, thereby turning on PMOS transistors 332 , 334 , 336 and 338 . When the transistors 332 and 338 are turned on, they provide a path for source voltage VDDIO to pull a node 340 to high. The high signal at the node 340 in effect will turn off the PMOS transistors 342 and 344 . With a low signal at the node 328 , when the gate of a post driver PMOS transistor 346 receives a high signal because of an inverter 348 , the transistor 346 will be turned off. A NMOS transistor 350 will be turned on since the high signal at the node 340 simply continues through a buffer 352 . When the transistor 350 is turned on, it helps pull the signal at the PAD 304 to low. As such, the output signal of the buffer 300 becomes the inverse of the input signal.
The tri-state mode occurs when the enable pin 302 is set to a high state. The input pin is also set to high, thereby helping to show how the buffer 300 operates in tri-state mode. Once again, the signals enter the low voltage tri-state logic control block 308 to determine when pull-down switches are to be opened or closed. The node 324 will carry a low signal since the inverter 312 inverts the high enable signal from the enable pin 302 , and this low signal also turns off the transistor 320 . The NAND gate 314 will take in the low signals from the node 324 and the inverter 310 to provide the node 326 with a high signal, thereby turning the transistor 318 on. The NAND gate 316 also takes in a high signal at the node 326 and a low signal at the node 324 , thereby giving the gate of the transistor 322 a high signal and turning the transistor 322 on. With the transistors 318 and 322 turned on, the nodes 328 and 340 are quickly pulled to low, thereby turning on the transistors 334 and 344 and allowing a high signal from the source voltage VDDIO to reach the gates of transistors 336 and 338 . This turns off both the transistors 336 and 338 , thereby shutting off power from the level shifter. The low signal at the node 328 turns the transistor 346 off after the signal goes through the inverter 348 , while the low signal at the node 340 turns the transistor 350 off after the low signal continues through the buffer 352 . With transistors 346 and 350 turned off, the output at the PAD 304 will have a high impedance.
FIG. 3B presents a truth table 354 in accordance with the second embodiment of the present invention. The truth table 354 shows the expected output signals for all three possible states with different combinations of enable or input signals.
FIG. 4 presents a diagram 400 illustrating the relationship between output and input signals in accordance with the first embodiment of the present invention. With reference to FIGS. 2A and 4 , the relationship is essentially between the output signal from the PAD 204 when the input signal of the input pin 206 , as well as the enable signal of the enable pin 202 from the first embodiment are being changed.
A curve 402 is the enable signal; it will remain at low state until 70 ns into the plot. A curve 404 shows the changes of the input signal. In this embodiment, the state of input signal is being changed around every 20 ns. The high state of the input signal is 1.2 volts, and low state is 0 volts. With reference to FIGS. 2A and 4 , this low voltage results from the input signal entering the buffer 200 before going through a level shifter. A curve 406 shows the response of the output signal during the changes of the curve 402 (enable signal) and the curve 404 (input signal). During the first 70 ns, the enable signal has no affect on the response of the output signal. Whenever the input signal is at a low state, the output signal would be at high and vice versa. The high state for the output signal is around 3.3 volts and the low state is 0 volts since all components after the tri-state control logic block 208 in FIG. 2A are supplied by the higher voltage source. As mentioned in the description of FIG. 2A , the input signal and output signal are inverse of each other if the enable signal is at a low state. However, when the enable signal turns high at 70 ns, the output signal drops out of existence since no signal can exit through the PAD 204 . The input signal can still be changed and would not affect the output signal.
This invention provides a solution to the cross-bar current issue while reducing the switching power and the pre-driver layout area by implementing a single tri-state level shifter. This invention features only one level shifter and some extra pull-up and pull-down switches. The differential outputs 228 and 230 of the level shifter control a pair of transistors 242 , 250 in the post driver circuit to determine the output signals. Such differential output of the level shifter provides a self-generated time differential to prevent cross-bar current from occurring during switching.
This invention saves switching power and pre-driver layout area by removing an entire level shifter and a plurality of timing balancing inverters. As a result, the post-driver switching power can be reduced by about 50 percent. Moreover, the proposed dual-voltage three-state buffer circuit is compatible with all existing technologies.
The above illustration provides many different embodiments or examples for implementing different features of the new designs of the dual-voltage three-state buffer circuit. Specific examples of components and processes are described to help clarify the invention. These are, of course, merely embodiments and are not intended to limit the invention from that described in the claims.
Although the invention is illustrated and described herein as embodied in one or more specific examples, 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. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention, as set forth in the following claims.
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A dual-voltage three-state buffer circuit controls a post driver circuit to operate in a three-state mode and includes a tri-state logic control module operated under a low supply voltage, a level shifter for receiving one or more inputs from the tri-state logic control module and operating with an output control circuit for controlling two differential outputs of the level shifter, and a post driver circuit driven by the two differential outputs of the level shifter, wherein the level shifter, the output control circuit, an the post driver circuit are operated under a high supply voltage, and wherein when the tri-state logic control module generates the inputs for putting the post driver circuit in a high impedance state, the output control circuit operates with the level shifter to turn off the PMOS and NMOS transistors of the post driver circuit while isolating the level shifter from a high supply voltage.
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BACKGROUND OF THE INVENTION
The present invention relates to a braking apparatus for a door closer.
In a door closing operation controlled by such a door closer, it is desired that either the closing operation be completely done at a fixed speed, or rapidly in an initial stage through a predetermined initial portion of the closure angular range and then fully closed more slowly in the remainder of the range. The speed change is effected by an adjusting valve or the like.
Such a conventional door closer, however, cannot properly resist an external force such as wind pressure acting on the door during the door closing direction. In such a case, the door may be rapidly fully closed even in the remaining part of the angular range, thereby causing damage to the door or its attachments, or the door frame, or smashing someone's finger or hand. Hence, the conventional door closer involves substantial safety problems.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to eliminate the above-mentioned disadvantages in the prior art door closers.
It is another object of the present invention to provide a braking apparatus for a door closer in which, while the door is closing at a speed adjusted by a slide valve in a normal state, the door is provided with resistance to external forces acting in the door closing direction in such a manner that the slide valve is actuated by stopping the flow of operating oil to thereby cause the door to stop and then close slowly.
In order to attain the above objects, a door closer is provided including a rotor mounted within an operating cylinder. A first pressure chamber and a second pressure chamber are formed in the operating cylinder, and a check valve is provided on a blade within the cylinder. When the door is opened, a torsion spring is subject to torsion by a main shaft to thereby rotate the rotor so as to open the check valve and allow operating oil in the second pressure chamber to flow into the first pressure chamber through a first oil hole. When the door is closed, the rotor and the main shaft are reversely rotated by the recovery force of the torsion spring to thereby close the door. In accordance with the invention, there is provided a braking apparatus for this door closer in which a second and a third oil hole are communicated to the second pressure chamber and the first pressure chamber, respectively, a communicating oil hole is formed in a circumferential wall of the cylinder so as to communicate with the second and third oil holes, and the braking apparatus comprises a slide valve arranged so as to be slidable in the communicating hole in the axial direction thereof, which slide valve is provided with a valve rod having a head portion and a braking valve portion formed at a top of the rod and a position corresponding to the third oil hole, respectively, and dimensioned so as to be tightly fitted in the communicating hole; an elastic member urging the slide valve in the direction opposite to the direction of flow of the operating oil when the door is closing so as to cause the slide valve to fit into the communicating hole; and an adjusting screw threadedly engaged with an opening portion of the communicating hole for positioning the slide valve in the axial direction.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawing wherein:
FIG. 1 is a front view, partially in section, showing a preferred embodiment of a braking apparatus for a door closer according to the present invention;
FIG. 2 is an enlarged cross section taken on a line II--II in FIG. 1; and
FIGS. 3 through 5 are enlarged cross sections showing various operating states of the braking apparatus in the embodiment of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention will now be described in detail with reference to the accompanying drawings.
Referring to FIGS. 1 and 2, a vertically elongated cylinder 1 has a lower small inner diameter portion 1a and an upper large inner diameter portion 1b. Corresponding to the inner diameter portions of the cylinder 1, a rotor 2 has a lower small diameter portion 2a and an upper large diameter portion 2b. The rotor 2 is rotatably fitted into the cylinder 1 in a fluid-tight manner with O-rings 5 and 6 respectively fitted in grooves 3 and 4 circumferentially formed in a peripheral wall of the cylinder 1 in the vicinity of the opposite ends thereof. Thus, an operating oil holding chamber 7 having a substantially annular cross section is defined between the large diameter portion 1b of the cylinder 1 and the small diameter portion 2a of the rotor 2.
The illustrated cylinder 1 has a closed lower end and an open upper end. A bearing member 8 for use also as an end plug is fixed by a stop ring 8a at the upper end opening of the cylinder 1 to thereby prevent the rotor 2 from coming off.
The rotor 2 has a hollow portion and a bottom portion. A main shaft 10 passes through the rotor 2 along the longitudinal center thereof.
The upper end of the main shaft 10 passes through a center hole 8a of the bearing member 8 so as to be supported by the bearing member 8, and an arm 11 is fixed to an outwardly projecting end 10a of the main shaft 10 by a stop screw 12 so as to be rotatable together with the main shaft 10. The lower end of the main shaft 10 passes through a through-hole 2c formed at the center of the bottom wall of the rotor 2 and projects outwards through a through-hole 1d formed in a bottom wall 1c of the cylinder 1. The lower projecting end 10b of the main shaft 10 is normally covered with a cover 13; however, the cover 13 can be removed as required so that the above-mentioned arm 11 can be fixed to the lower projecting end 10b.
A torsion spring 14 is provided in a space defined inside the rotor 2 between the inner circumferential surface of the rotor 2 and the main shaft 10. The upper and lower ends of the torsion spring 14 are fixedly engaged with the main shaft 10 and the rotor 2, respectively, so that the rotor 2 and the bearing member 8 are interlocked with each other and the torsion spring 14 is subject to torsion by the main shaft 10 rotated during the door opening operation. The torsion spring 14 is mounted in the space so as to contact the inner circumferential surface of the rotor 2 in such a manner as to not be bent relative to the center axis while under torsion.
Further, a defining wall 1f projects from the inner surface of a circumferential wall 1e of the cylinder 1 to circumferentially define the chamber 7, and the outer circumferential surface of the rotor 2 contacts in a fluid-tight manner with the inner surface of the defining wall 1f.
A blade 2d projects outwardly from the outer wall surface of the rotor 2 and contacts in a fluid-tight manner with the inner surface of the cylinder 1. The chamber 7 is divided into a second pressure chamber 7a and a first pressure chamber 7b by the blade 2d, the inner surface of the cylinder 1, and the defining wall 1f.
An oil hole 15 is formed in the blade 2d through which the second pressure chamber 7a and the first pressure chamber 7b can be communicated with each other. A self-closing check valve 16 is provided in the oil hole 15 at the first pressure chamber 7b side so that the check valve 16 is opened by the pressure of the operating oil owing to the clockwise rotation of the rotor 2 in FIG. 2 caused by the door opening operation.
Oil holes 17 and 18 respectively communicating with the second pressure chamber 7a and the first pressure chamber 7b are formed in the circumferential wall 1e of the cylinder 1 at the opposite sides of the defining wall 1f, and a communicating oil hole 19 is formed in the circumferential wall le of the cylinder 1 transversely in the direction substantially perpendicularly to the longitudinal direction of the cylinder 1 so as to communicate with the holes 17 and 18.
The illustrated communicating oil hole 19 has its bottom end closed and the other end opened to form an opening portion 19a. The opening portion 19a is made larger in diameter than other portions and is threaded at the inner surface thereof to define a screw hole 19b.
A slide valve 20 is fitted in the communicating oil hole 19 so as to be axially slidable. The slide valve 20 is provided with a valve rod 20a reduced in diameter by a suitable value with respect to the inner diameter of the communicating oil hole 19. The valve rod 20a has a head portion 20b formed at a position on the valve rod 20a corresponding to the communicating oil hole 19 at the first pressure chamber 7b side. The head portion 20b and the valve portion 20c are shaped to fit in the communicating oil hole and are axially separated from each other by a distance larger than the interval between the oil holes 17 and 18. An elastic member 21, disposed inside the communicating oil hole 19, is supported at its opposite ends by a bottom portion 19c of the communicating oil hole 19 and the above-mentioned head portion 20b so that the slide valve 20 is urged by the spring force of the elastic member 21 in the direction counter to the operating oil flow direction in the door closing operation, that is, in the downward direction in FIG. 2. The slide valve 20 is supported at it rear end by an adjusting screw 22 screwed into an opening portion of the communicating oil hole 19. Hence, not only is the slide valve 20 prevented from coming off, but also the axial position of the slide valve 20 can be adjusted by advancing/retreating the adjusting screw 22.
That is, the slide valve 20 is normally adjusted by the adjusting screw 22 so as to be held at the position shown in FIG. 2 in which the communicating oil hole 19 communicated with the oil holes 17 and 18 is not closed by the valve portion 20c so that, in the door closed state shown in FIG. 2, the second pressure chamber 7a and the first pressure chamber 7b are maintained in communication with each other because the communicating oil hole 19 is communicated with each of the oil holes 17 and 18.
Further, the adjusting screw 22 is threadedly engaged with the screw hole 19b of the communicating oil hole 19 in a fluid-tight manner through an O-ring 23.
The cylinder 1 is fixed to a door (not shown), and the top end of the arm 11 is pivotally attached to the top end of another arm (not shown) having a base end pivoted to a door attaching frame (not shown).
In such an arrangement, when the door is opened, the main shaft 10 is rotated clockwise by the arm 11 from the position in the closed state shown in FIG. 2. Simultaneously, the torsion spring 14 is twisted in the same direction as the main shaft so as to rotate the rotor 2 clockwise, as indicated by an arrow a in FIG. 3, and the blade 2d is also rotated in the same direction so that the check valve 16 is opened by the operating oil at that time to allow the operating oil in the second pressure chamber 7a to flow into the first pressure chamber 7b through the oil hole 15. Thus, the door can be opened through a predetermined angular range.
When the door opening force is released, the check valve 16 is closed and the rotor 2 and the main shaft 10 receive a rotating force due to the recovery force of the torsion spring 14, this force acting counter-clockwise in FIG. 3, that is, in the direction of an arrow b in FIG. 4, so that the operating oil in the first pressure chamber 7b flows into the second pressure chamber 7a through the oil hole 18, the communicating oil hole 19, and the oil 17. Thus, the rotor 2 and the main shaft 10 are rotated in the direction of the arrow b to close the door. The flow rate of the operating oil is adjusted by the slide valve 20, the position of which is set by the adjusting screw 22 and the elastic member 21.
If an external force such as wind pressure or the like is exerted on the door in the door closing direction when the door is being closed, the rotor 2 receives a rotating force in the direction indicated by the arrow b in FIG. 4 through the arm 11 and the main shaft 10. Hence, the first pressure chamber 7b is pressurized so that the interior pressure thereof rapidly increases, and the force created by the inner pressure applied to the side surface 20d of the valve portion 20c of the slide valve 20 becomes larger than that in the normal state described above. Accordingly, the slide valve 20 slides upwardly in the drawing while compressing the elastic member 21 so that the valve portion 20c cuts off communication between the oil hole 18 and the communicating oil hole 19 to inhibit the operating oil from flowing and to thereby brake the movement of the door.
When the external force in the door closing direction is removed, the inner pressure of the first pressure chamber 7b is decreased to the normal state, whereby the slide valve 20 is slid downwardly in the drawing by the spring force of the elastic member 21 from the state of FIG. 5 to return to the state of FIG. 4, and hence the flow path of the operating oil, which was blocked by the valve portion 20c, is opened so that the normal door closed state is recovered.
The spring constant of the elastic member 21 is selected so that the elastic member 21 is not compressed in the normal door closing operation.
In the illustrated embodiment, a compression spring is used as the elastic member 21. However, the elastic member is not limited to this construction, but, for example, may be made of urethane, a rubber material, or the like.
Although the apparatus according to the invention is described with reference to a vertical-type door closer in the illustrated embodiment, the invention is not limited to this application, and can be applied to a horizontal-type door closer.
As described above, the braking apparatus for a door closer according to the present invention is arranged such that the communicating oil hole 19 is formed in the circumferential wall 1e of the cylinder 1 so as to communicate with each of the oil holes 17 and 18 respectively communicated with a second pressure chamber 7a and a first pressure chamber 7b formed in the cylinder 1, and a slide valve 20 provided with a valve rod 20a having a head portion 20b and a valve portion 20c, which are enlarged in diameter and formed at a top end portion and a position corresponding to the oil hole 18, respectively, is slidably disposed in the communicating hole 18 in a such manner that the slide valve 20 is urged by an elastic member 21 in the direction opposite to the operating oil flow direction in the door closing operation. The position of the slide valve 20 can be adjusted by the elastic member 21 and an adjusting screw 22.
Accordingly, not only can the door opening/closing speed be adjusted as desired by suitably adjusting the amount of flow of the operating oil, but, in the case where an external force acting in the door closing direction is applied in the door closing operation, the force exerted on the valve portion 20c of the slide valve 20 becomes large owing to the increase in the inner pressure of the first pressure chamber 7b so as to make the slide valve 20 slide against the spring force of the elastic member 21 to thereby cut off communication between the communicating oil hole 19 and the oil hole 18 of the first pressure chamber 7b with the valve portion 20c, so as to stop the operating oil from flowing, and to thereby brake the door and hence prevent the door from closing rapidly. Further, since the slide valve 20 contacts the inner surface of the communicating hole 19 at two portions, namely, the head portion 20b and the valve portion 20c, the slide valve 20 slides smoothly when the inner pressure of the pressure chamber 7 rises rapidly, as described above, so that tilting of the slide valve 20 never occurs, the valve operation can be surely performed, and the braking operation can be carried out accurately.
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An improved door closer which prevents overly rapid closing due to an external force, such as wind pressure, being exerted on the door. A pair of oil holes are formed communicating with a first pressure chamber and a non-pressure chamber formed in the main cylinder of the closer. A slide valve is disposed in a communicating hole communicating with the oil holes and extending generally perpendicular to the cylinder. A head portion and a braking valve portion are formed on the valve rod of the slide valve at positions corresponding to the oil holes. An elastic member urges the slide valve in the direction opposite to the normal flow direction of the operating oil when the door is closing. An adjusting screw controls the position of the slide valve.
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BACKGROUND OF THE INVENTION
[0001] This application relates to the delivery of sterilant from a cassette to an instrument sterilizer, and more particularly to the extraction of sterilant from the cassette.
[0002] One popular method for sterilizing instruments, such as medical devices, is to contact the devices with a vapor phase chemical sterilant, such as hydrogen peroxide. In many such sterilizers, it is preferred to deliver the sterilant in liquid form and vaporize it in the sterilizer. One particularly convenient and accurate method for delivering the liquid sterilant is to put a predetermined quantity of sterilant into a cassette and deliver the cassette to the sterilizer. The sterilizer then automatically extracts the sterilant from the cassette and uses it for sterilization procedure. Typically, such a cassette would entail multiple cells containing equal amounts of liquid sterilant with a sterilization procedure employing the sterilant from one or more cells. Such a system is currently available in the STERRAD® sterilization system available from Advanced Sterilization Products in Irvine, Calif.
[0003] U.S. Pat. Nos. 4,817,800; 4,869,286; 4,899,519; 4,909,287; 4,913,196; 4,938,262; 4,941,518; 5,882,611; 5,887,716; and 6,412,340, each incorporated herein by reference, disclose such cassettes and a method for draining liquid sterilant from a cell within a cassette.
[0004] If an operator employs a cassette which has already been used, time can be wasted before the operator realizes that no sterilant has reached the articles during the failed sterilization cycle. A convenient disposal method for spent cassettes would also be desirable.
[0005] The present invention overcomes these and other limitations of the prior art.
SUMMARY OF THE INVENTION
[0006] A method according to the present invention for tracking sterilant cassettes within a sterilizer includes the steps of: reading for the presence of a cassette within a cassette processing area of the sterilizer by transmitting a non-optical electromagnetic signal between the cassette and a receiver on the sterilizer; via the electromagnetic signal transmitting identifying information between the cassette and the receiver; and verifying that a proper cassette is loaded into the sterilizer based upon the identifying information.
[0007] The electromagnetic signal can comprise, for instance, a magnetic coupling between the receiver and the cassette, or an inductive coupling between the receiver and the cassette, or a conductive coupling between the receiver and the cassette, or a radio frequency transmission.
[0008] Preferably, the receiver comprises one or more antennas, preferably sequenced in use to identify the location of the cassette.
[0009] Preferably, the cassette contains an RFID tag.
[0010] The method preferably further includes the step of altering a portion of data stored in the RFID tag, such as filling status of sterilant in the cassette and the filling status data is updated when sterilant is removed from the cassette. Where the cassette contains multiple cells containing the sterilant preferably, the RFID tag includes a filling status of sterilant in each of the cells and the filling status data for a cell is updated when sterilant is removed from that cell. If less than the entire contents of one of the cells is removed, preferably this data is stored on the tag.
[0011] In one aspect of the invention, the RFID tag contains temperature sensing instrumentation and the data includes temperature information regarding the shipping and storage temperatures to which the cassette has been subjected.
[0012] In another aspect of the invention, the data is updated with one or more cycle parameters, such as a concentration of sterilant achieved during a cycle.
[0013] Updateable data can also include the amount of time the cassette has spent within the sterilizer. Identifying data can include the type of cycle for which a particular cell or group of cells is intended (such as cycle times, amount of sterilant to be used etc.). It could also include an expiration date for the cassette and the method further include the step of rejecting the cassette if the expiration date has passed.
[0014] Preferably, the method further includes the step of reading the presence and filling status of a spent cassette collection box via a non-optical electromagnetic signal.
[0015] A cassette, according to the present invention, comprises one or more cells having therein a liquid sterilant, and further comprises indicia readable electromagnetically and containing identifying data about the cassette including data identifying the liquid sterilant contents thereof.
[0016] The data can include such things as a filling status of the cells, an expiration date of the liquid sterilant, a manufacturing date of the cassette, a serial number of the cassette, a lot number of the cassette, and a maximum amount of time the cassette may reside within a sterilizer.
[0017] Preferably, the indicia comprises an RFID tag, more preferably an RFID tag with updateable memory. The updateable memory can contains such data as the filling status of the one or more cells within the cassette data regarding the cell being partially filled, temperature information regarding the shipping and storage temperatures to which the cassette has been subjected, one or more cycle parameters (such as a concentration of sterilant achieved during a cycle), and the amount of time the cassette has spent within a sterilizer.
[0018] A spent cassette collection box for receiving spent cassettes from a sterilizer, according to the present invention, comprises a bottom wall, upstanding walls attached to the bottom wall which extend upwards to terminate in an upper edge, and indicia readable electromagnetically and containing identifying data about the spent cassette collection box including data identifying its capacity to receive cassettes.
[0019] Preferably, the indicia is an RFID tag and more preferably, is an RFID tag having updateable data including a quantity of cassettes currently in the box.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a block diagram of a sterilizer employing a cassette handling system according to the present invention;
[0021] FIG. 2 is a rear perspective view of a cassette handling system according to the present invention;
[0022] FIG. 3 is a front perspective view of the cassette handling system of FIG. 2 ;
[0023] FIG. 4 is a front perspective view of the cassette handling system of FIG. 2 showing a spent cassette collection box;
[0024] FIG. 5 is a rear perspective view of the cassette handling system of FIG. 2 showing its carriage in the insert position;
[0025] FIG. 6 is a rear perspective view of the cassette handling system of FIG. 2 showing its carriage as it moves toward the home position;
[0026] FIG. 7 is a rear perspective view of the cassette handling system of FIG. 2 showing its carriage in position to read a bar code on the cassette;
[0027] FIG. 8 is a rear perspective view of the cassette handling system of FIG. 2 showing its carriage in the home position;
[0028] FIG. 9 is a front perspective view of the cassette handling system of FIG. 2 showing its carriage in position to tap the cassette's first cell;
[0029] FIG. 10 is a cross sectional view of the cassette showing a cell therein;
[0030] FIG. 11 is a front perspective view of the cassette handling system of FIG. 2 showing upper and lower needles on an extractor subsystem penetrating the first cell of the cassette;
[0031] FIG. 12 is a front perspective view of the cassette handling system of FIG. 2 showing upper and lower needles on the extractor subsystem in position to penetrate the last cell of the cassette;
[0032] FIG. 13 is a front perspective view of the cassette handling system of FIG. 2 showing the cassette being ejected therefrom;
[0033] FIG. 14 is a flow chart of the cassette handling process;
[0034] FIG. 15 is a rear perspective view of an alternative embodiment of a cassette handling system of the present invention employing RFID technology;
[0035] FIG. 16 is a memory map of an RFID tag of the cassette shown in FIG. 15 ;
[0036] FIG. 17 is a top plan view of an unfolded blank for forming the spent cassette collection box of FIG. 4 ; and
[0037] FIG. 18 is a perspective view of the blank of FIG. 17 folded to form the spent cassette collection box.
DETAILED DESCRIPTION
[0038] FIG. 1 shows in block diagram form a vapor phase sterilizer 10 employing a cassette handling system 12 according to the present invention. The sterilizer 10 comprises a vacuum chamber 14 and a vacuum pump 16 for exhausting atmosphere therefrom. A vaporizer 18 receives liquid sterilant from the cassette handling system 12 and supplies it in vapor form to the vacuum chamber 14 . A screen grid electrode 20 is provided within the vacuum chamber 14 for exciting the contents into the plasma phase during a portion of the sterilization cycle. A micro filtered vent 22 and valve 24 allow sterile air to enter the vacuum chamber 14 and break the vacuum therein. A control system 28 ties in to all of the major components, sensors and the like within the sterilizer 10 to control the sterilization cycle.
[0039] A typical sterilization cycle might include drawing a vacuum upon the vacuum chamber 14 and turning on power to the electrode 20 to evaporate and extract water from the vacuum chamber 14 . The electrode 20 is then powered off and a low vacuum of less than 1 torr drawn on the vacuum chamber 14 . Sterilant, such as hydrogen peroxide solution, is vaporized by the vaporizer 18 and introduced into the vacuum chamber 14 where it diffuses into contact with the items to be sterilized and kills microorganisms thereon. Near the end of the cycle, power is again applied to the electrode 20 and the sterilant is driven into the plasma phase. The electrodes 20 are powered down and filtered air is drawn in through the valve 24 . This process can be repeated.
[0040] Turning also to FIGS. 2 to 4 , the cassette handling system 12 according to the present invention is shown. It comprises in gross, a carriage 32 for holding a cassette 34 , a lead screw 36 and motor 38 , an extractor subsystem 40 and a scanner 42 .
[0041] The carriage 32 comprises a bottom panel 44 , a side panel 46 and top panel 48 along with small vertical flanges 50 and 52 on the top and bottom and top panels 48 and 44 , respectively, to capture the cassette 34 . The bottom, side and top panels 44 , 46 and 48 flare outwardly at an entrance 54 of the carriage to aid in insertion of the cassette 34 . Two spring catches 56 on the flanges 50 and 52 engage irregular surfaces of the cassette 34 to firmly position the cassette 34 within the carriage 32 .
[0042] The carriage 32 travels along the lead screw 36 and is supported on an upper rail 58 . A lead screw nut 60 attached to the bottom panel 44 and having a threaded opening 62 and an unthreaded opening 63 receives the lead screw 36 and effects horizontal movement of the carriage 32 in response to rotations of the lead screw 36 . Flanges 64 extend outwardly from the top panel 48 and flanges 66 extend outwardly from the side panel 46 each having openings 69 for receiving the upper rail 58 . The motor 38 is preferable a stepping motor and connects to the lead screw 36 to precisely control the horizontal position of the cassette 34 relative to a frame 68 .
[0043] The extraction assembly 40 comprises an upper needle 70 and a lower needle 72 , each being of a lumened configuration. The upper needle connects to an air pump 74 which can force air out through the upper needle 70 . The lower needle 72 connects to a valve 76 and from there is plumbed to the vaporizer 18 .
[0044] The scanner 42 is oriented so as to be able to read a barcode 80 on the cassette 34 as well as a barcode 82 on a spent cassette collection box 84 . Upon insertion of the cassette 34 into the carriage 32 the scanner 42 reads the cassette barcode 80 . The barcode 80 is preferably encoded with information regarding the contents of the cassette 34 , including lot numbers and expiration dates. This information can be used to determine whether the cassette 34 is fresh and of the correct type and whether the cassette 34 has been used in the system before and thus is at least partially empty. The code is communicated to the control system 28 which makes these determinations.
[0045] The scanner 42 can also see the spent cassette collection box barcode 82 when the carriage 32 moves inwardly and away from the scanner 42 . Each spent cassette collection box 84 preferably has two barcodes 82 , one in each opposing corner so that the scanner 42 can see one of them regardless of which end of the spent cassette collection box 84 is inserted first. With the spent cassette collection box 84 filled, the spent cassettes 34 block the barcode 82 which alerts the control system 28 that there is no capacity for receiving additional spent cassettes 34 . Preferably this message will be output to a user, such as on a display screen (not shown). If the cassette 34 is empty it will not be ejected and no new cycles will be run until a spent cassette collection box 84 having capacity to receive a spent cassette 34 is placed into the sterilizer 10 .
[0046] A forward flag 86 and rearward flag 88 project outwardly and downwardly from the carriage side panel 46 . They slide through a slot 90 in a slot sensor 92 which detects their presence within the slot 90 , such as by blocking a beam of light. Travel of the front flag 86 and rear flag 88 through the slot sensor 92 provides a reference location of the carriage 32 to the control system 28 .
[0047] The top panel 48 of the carriage 32 can rotate about the upper rail 58 . A spring 94 between the top panel 48 and side panel 46 biases the top panel 48 downwardly to hold the cassette 34 within the carriage 32 . A disposing cam 96 sits behind the side panel 46 and aligns with an ejecting tab 98 which extends outwardly and downwardly from the top panel 48 and which can project through an opening 100 in the side panel 46 when the top panel 48 rotates upwardly. Such rotation of the top panel 48 releases its hold upon the cassette 34 and due to the ejecting tab 98 projecting through the opening 100 pushes the cassette 34 out of the carriage 32 and into the spent cassette collection box.
[0048] The disposing cam 96 controls rotation of the top panel 48 . It comprises a generally triangular shape, having an outwardly facing side 102 , forwardly facing side 104 and rearwardly facing side 106 . Turning also now to FIG. 5 , it mounts for rotation upon an upwardly extending spindle 108 . A spring 110 biases the disposing cam 96 counterclockwise, urging the outwardly facing side 102 into contact with an abutment 112 . Inward movements of the carriage 32 allow the ejecting tab 98 to cam over the rearwardly facing side 106 of the disposing cam 96 , thus allowing the disposing cam 96 to rotate clockwise and allow the ejecting tab 98 to pass thereby without effecting rotation of the top panel 48 . However, outward movement of the carriage 32 causes the ejecting tab 98 to cam over the forwardly facing side 104 of the disposing cam 96 . During such motion contact between the outwardly facings side 102 of the disposing cam 96 and the abutment 112 prevents rotation of the disposing cam 96 . The camming of the ejecting tab 98 thus causes it to move laterally toward the side panel 46 thereby rotating the top panel 48 upwardly and releasing the cassette 34 from the carriage 32 .
[0049] Prior to inserting the cassette 34 the carriage 32 is fully retracted to its outward position (to the left as shown in FIG. 5 ). In this position also, a forward end 114 on the lead screw nut 60 engages a stop 116 thus positively locating the position of the carriage 32 . Turning also now to FIG. 6 , manual insertion of the cassette 34 causes the carriage 32 to move inwardly (to the right as shown in FIG. 6 ) and moves the front flag 86 into the slot sensor 92 . This movement is preferably caused by the physical force from inserting the cassette 34 , however, a torque or other sensor could be applied to allow the stepping motor 38 to take over this movement upon feeling the force of the cassette 34 being inserted into the carriage 32 . Allowing this movement to come from the force of the insertion of the cassette 34 ensures that the cassette 34 is fully seated within the carriage 32 before the movement begins.
[0050] Once the front flag 86 is read by the slot sensor 92 the stepper motor 38 takes over and starts to move the carriage 32 inwardly. Turning also now to FIG. 7 , during this stage, the scanner 42 scans the barcode 80 on the cassette 34 . The control system 28 interprets the information coming from the barcode 80 and determines whether the cassette 34 has been used in the sterilizer 10 before, whether the cassette contains fresh sterilant, and other data as appropriate. Preferably, the information on the barcode 80 is encrypted to prevent unauthorized parties from creating cassettes which may not meet the quality standards necessary for proper sterilization.
[0051] If the control system 28 rejects the cassette 34 a carriage 32 is moved sufficiently inwardly so as to pass the ejecting tab 98 past the disposing cam 96 and is then moved back to the insertion position shown in FIG. 5 to eject the rejected cassette 34 . If the cassette 34 is accepted, the carriage 32 continues inward movement to the home position as shown in FIG. 8 in which the rear flag 88 has just passed out of the slot sensor 92 .
[0052] Turning also now to FIGS. 9 and 10 , the cassette 34 comprises a plurality of cells 118 containing liquid sterilant 120 . Various structures of a cassette may be employed. The cassette 34 shown comprises a hard outer shell 122 , preferably formed of an injection molded polymer, such as high impact polystyrene, high density polyethylene or high density polypropylene, which encloses the individual cells 118 , the cells 118 being formed of a blow molded polymer such as low density polyethylene. However, a more rigid material can be used to form the cassette cells 118 in which case the outer shell 122 could be omitted. In the cassette 34 shown, an upper aperture 124 and lower aperture 126 through the shell 122 allows the upper and lower needles 70 and 72 to penetrate the shell. The cell 118 is formed of a material easily penetrated by the needles. If the cell 118 is formed of a more substantial material, a thinning of the material could be provided at the locations to be penetrated by the needles 70 and 72 .
[0053] The control system 28 uses the home position of FIG. 8 as a reference position for positioning the various cells 118 in front of the extractor subsystem 40 . By moving the carriage 32 a predetermined amount from the home position a given cell 118 can be brought to face the extractor system 40 . In FIG. 9 , cell one has been placed in front of the extractor system 40 . Turning also now to FIG. 11 , an actuator 128 drives the extractor subsystem 40 toward the cassette 34 causing the upper and lower needles 70 and 72 to penetrate the upper and lower apertures 124 and 126 and enter the cell 118 . After the needles have fully extended, the air pump 74 drives air into the cell 118 through the upper needle 70 . The system waits a couple of seconds before starting the air pump 74 and opening the valve 76 to ensure proper placement and settling of the needles within the cell 118 . The sterilant 120 flows out through the lower needle 72 and is piped off to the vaporizer 18 . After a sufficient time to extract the sterilant 120 , the air pump 74 switches off and the actuator retracts the extractor subsystem 40 from the cassette 34 .
[0054] The vaporizer 18 connects to the vacuum chamber 14 which allows the lower needle 72 to easily be placed at a pressure below atmospheric. Thus, the pump 74 can optionally be replaced by a valve (not shown) open to atmosphere, in which case the incoming atmospheric pressure air will provide the driving force to empty the cell 118 .
[0055] Rather than employ upper and lower needles 70 and 72 , one needle having two lumens therethrough would suffice. One of the lumens would provide pressurizing gas and one would extract liquid sterilant. A further alternative arrangement would be to pierce the cell 118 vertically, or substantially so, from an upper part of the cell 118 , preferably with such a double lumen needle. This would minimize leakage around the hole created by the needle entering the cell 118 . Such entry would also allow the tip of the needle to come closer to the lowest point of the cell 118 for maximum extraction efficiency. If one desired to extract less than all of the contents of the cell 118 , one method would be to position the needle extracting the sterilant, such as the lower needle 72 or the just mentioned double lumen needle, at the level in the cell 118 down to which extraction is desired. Liquid sterilant above the position would be extracted and sterilant below would remain. This would be particularly convenient with the just mentioned vertically traveling needle.
[0056] Turning also to FIG. 12 , each time the control system 28 determines that a new dose of sterilant 120 is required, the stepper motor 38 moves the cassette to position the next cell 118 in front of the extractor subsystem 40 and a new extraction takes place. Multiple extractions may be employed for a given sterilization cycle. When the cassette 34 has been depleted, the carriage 32 moves towards the insert position thus causing the ejecting tab 98 to cam over the disposing cam 96 to rotate the top panel 48 upwardly and project the ejecting tab 98 through the opening 100 to drive the cassette 34 out of the carriage 32 as described above and as shown in FIG. 13 . The cassette 34 falls into the spent cassette collection box 84 and the carriage 32 returns to the insertion position as shown in FIG. 5 .
[0057] The foregoing discussion described the operation of the cassette handling system in some detail. FIG. 14 shows, in block diagram form, the basic operation of the cassette handling system 12 .
[0058] The system of reading barcodes on the cassette 34 and spent cassette box 84 can be replaced with radio frequency identification tags, commonly known as RFID tags. An RFID system 130 is shown in FIG. 15 . It comprises a controller 132 connected via an SPDT reed relay 134 to a cassette insertion antenna 136 located on the carriage 32 and a cassette disposal antenna 138 located beneath the spend cassette box 84 . Each cassette 34 carries a cassette RFID tag 140 . Similarly, each spent cassette collection box 84 carries a collection box RFID tag 142 . Preferably, the controller 132 comprises a Texas Instruments multifunction reader module S 4100 and the RFID tags 140 and 42 comprise Texas Instruments RFID tag RI-101-112A each of which are available from Texas Instruments, Dallas, Tex.
[0059] The control system 28 ( FIG. 1 ) selects one of the antennas, as for instance the cassette insertion antenna 136 and sends a signal to the relay 134 to engage this antenna with the RFID controller 132 . The antenna reads the information stored on the cassette insertion RFID tag 140 which identifies the cassette 34 and its contents. The information read is similar to the information read using the barcode, however preferably, the RFID tag 140 has the ability to update the information stored thereon. Accordingly, additional data such as the filling status of individual cells 118 within the cassette 34 can be stored on the RFID tag. Thus, if the cassette 34 is removed and then reinserted into the sterilizer 10 , or even into different sterilizer 10 , the control system 28 can be apprised of the status of each of the individual cells 118 within the cassette 34 . This allows the reuse of a partially used cassette 34 . Also, since the RFID tag 140 can hold more data than the barcode 80 , more data about the cassette 34 , its contents and manufacturing can be included thereon.
[0060] The spent collection box antenna 138 reads the spent collection box RFID tag 142 to determine the presence or absence of the spent cassette collection box 84 . Other data such as a unique identifier for the box 84 , the capacity of the box 84 , how many cassettes 34 are currently in the box 84 and how many of the cells 118 therein are not empty can be included on the RFID tag 142 . The control system 28 can track how many cassettes 34 have been ejected into the box to determine whether it has room for more spent cassettes 34 . The antenna 138 can also read the cassette RFID tags 140 and count the number of cassettes 34 within the box 84 . When the box 84 is full the control system 28 alerts the operator, as by a message on a screen. This message can also include information regarding the cassettes 34 within the box 84 . For instance if not all of the cassettes 34 have been completely drained the operator can be informed of this to decide if more careful disposal may be indicated.
[0061] RFID technology is disclosed in the following U.S. patents, each of which is incorporated herein by reference: U.S. Pat. Nos. 6,600,420; 6,600,418; 5,378,880; 5,565,846; 5,347,280; 5,541,604; 4,442,507; 4,796,074; 5,095,362; 5,296,722; 5,407,851; 5,528,222; 5,550,547; 5,521,601; 5,682,143 and 5,625,341.
[0062] RFID tags typically comprise an antenna and an integrated circuit produced in a thin form factor so they can be inconspicuously placed upon an object such as the cassette 34 . Radio frequency energy sent by the antennas 136 and 138 induce sufficient current within the antenna inside the RFID tags 140 and 142 to power the integrated circuit therein. Some types of RFID tags carry their own power source and have longer detection ranges, but that adds additional expense and is probably not justified for the present use.
[0063] FIG. 16 shows the memory map for the memory within the RFID tags 140 and 142 . A 64-bit unique ID (UID) is set at the factory and cannot be changed. Each RFID tag has its own unique number here. Sixty-four 32-bit blocks can be programmed by the user. These can be populated with information such as the manufacture date, expiration date, product ID, serial number, lot numbers, manufacturing location, filling status of the cells, strength and type of sterilant, time spent within the sterilizer 10 and the like.
[0064] Some sterilants are affected by heat. The RFID tag 140 can optionally include temperature collection instrumentation and update that information on the tag. If design temperature profiles are exceeded, such as a maximum temperature or excessive temperature over a time period, then the cassette 34 can be rejected by the control system 28 . Temperature measuring RFID tags are available from KSW-Microtec, Dreseden, Germany and from Identec Solutions, Inc., Kelowna, British Columbia, Canada. The interior of the sterilizer 10 where the cassette 34 sits may be higher than ambient temperature. Thus, it may be beneficial to put a maximum residence time (on board shelf life) on the tag 140 or even to update on the tag 140 this time the cassette has already spent inside of the sterilizer.
[0065] To test sterilant measuring equipment in the sterilizer 10 , it may be beneficial to provide cassettes 34 having water or other fluids within one or more cells 118 . Information regarding the special nature of the cassette 34 and its contents could be written onto the RFID tag.
[0066] During a cycle the sterilizer may only require part of the contents of a cell 118 . For instance, a particular cycle may call for the contents of one and a half cells. The half filled nature of the cell 118 can be stored and then for the next cycle that cell 118 can be drained.
[0067] Preferably, communications between the tag 140 and 142 and the controller 132 are encrypted. For instance, the UID can be XORed with an eight-bit master key to form a diversified key for encrypting the data. Encryption algorithms such as the data encryption standard (DES) triple DES, asymmetrical encryption standard (AES) or RSA security can be used for the encryption. The RFID controller 132 reads the data and the algorithm in the control system 28 decrypts the data to reveal the stored information.
[0068] Other methods could be used to communicate between the cassette 34 and the sterilizer 10 . For instance information could be stored magnetically on the cassette 34 , such as with a magnetic encoded strip, and be read by a magnetic reader on the sterilizer. Wireless technology is becoming cheaper every day and it is envisioned that the cassette 34 could include an active transmitter and a power source (i.e. a battery) such as powered RFID tags or Bluetooth, 802.11b or other communication standard.
[0069] Further, the sterilizer 10 can be set up to communicate back to a central source, such as the manufacturer or distributor thereof, and provide information regarding its performance and the performance of the cassettes 34 . Poorly performing cassettes 34 could be identified, as for instance sterilant monitors in the sterilizer not detecting sterilant during a cycle thus indicating some failure such as an empty cassette or bad sterilant therein. An improperly manufactured batch of cassettes 34 could then be quickly identified and recalled. Such communication could occur over telephone, pager or wireless telephone networks or over the Internet.
[0070] Turning now also to FIGS. 17 and 18 , the spent cassette collection box 84 is preferably folded from a single sheet of printed cardboard or other stock. FIG. 17 shows an unfolded blank 150 and FIG. 18 shows the blank 150 folded to form the spent cassette collection box 84 .
[0071] The blank 150 is divided by a series of fold lines (shown dashed) and cut lines into a bottom panel 152 , side panels 154 , end panels 156 and top flaps 158 . Folding tabs 160 extend laterally from the side panels 154 . Additional folding tabs 162 extend laterally from the end panels 156 . Barcodes 82 are printed on the side panels 154 in a position to be visible in an upper interior corner of the spent cassette collection box 84 when it is folded into the configuration shown in FIG. 18 . A pair of top flap locking tabs 164 extend from the top flaps 158 and fit into slots 166 in the opposing top flap 158 when the box 84 is closed and into slots 168 at the intersection of the bottom panel 152 and side panel 154 when the box 84 is opened.
[0072] To fold the box, the folding tabs 160 on the side panels 154 are folded upwardly and then the side panels 154 are folded upwardly, thereby aligning the folding tabs 160 with the intersection between the bottom panel 152 and the end panels 156 . The end panels 156 are then folded upwardly and the end panel folding tabs 162 are folded downwardly over the folding tabs 160 . Locking tabs 170 on the end panel folding tabs 162 fit into slots 172 at the intersection between the bottom panel 152 and end panels 156 .
[0073] To place the box 84 into the open position as shown in FIG. 18 , the top flaps 158 are folded downwardly to the outside and the locking tabs 164 fitted into the slots 168 . Once the box 84 is filled with spent cassettes, the top flaps 158 are folded upwardly over the top and the locking tabs 164 can then be fitted into the slots 166 on the opposing top flaps 158 . This unique folding arrangement allows spent cassettes 34 to fall into the open box 84 easily without the top flaps 158 getting in the way and also allows easy closure of the box 84 once it has become filled.
[0074] While the invention has been particularly described in connection with specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and that the scope of the appended claims should be construed as broadly as the prior art will permit.
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A cassette handling system for sterilant filled cassettes employs RFID or other electromagnetic signal technology to track the cassettes. A method for tracking the sterilant cassettes includes the steps of reading for the presence of a cassette within a cassette processing area of the sterilizer by transmitting a non-optical electromagnetic signal between the cassette and a receiver on the sterilizer, via the electromagnetic signal transmitting identifying information between the cassette and the receiver, and verifying that a proper cassette is loaded into the sterilizer based upon the identifying information.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for driving a plasma display panel (PDP) device, and more particularly to the supply of the discharge voltage to the electrodes of the plasma display panel.
2. Description of the Prior Art
In general, a plasma display panel of an AC type has a first and a second plurality of electrodes which are disposed to traverse each other in the form of a matrix and are covered with dielectric layers. A discharge is formed in a confined discharge gas between the electrodes at a cross point of one of the first electrodes and one of the second electrodes.
A prior art driving circuit of a plasma display panel is illustrated in FIG. 1, and a time chart of the operation of the device of FIG. 1 is illustrated in FIG. 2.
X-directional electrodes 21, 22,-, 2n and Y-directional electrodes 31, 32,-, 3n of a plasma display panel 1 are supplied with voltage sustaining voltages V S and information writing-in voltages V W , -V W by a drive circuit 4 which comprises a switching network with transistors and diodes. Dischargeable spots are formed by cross points between the X-directional electrodes 21, 22,-, 2n and the Y-directional electrodes 31, 32,-, 3n.
If a signal x(al) is applied during the period t 1 to t 2 , and a signal x(bl) is applied during the period t 2 to t 3 , an output voltage V(xl) is supplied to the electrode 21, during the period t 1 to t 2 , as illustrated in (1), (2) and (3) of FIG. 2.
If a signal y(al) is applied during the period t 4 to t 5 , and a signal y(bl) is applied during the period t 5 to t 6 , an output voltage V(yl) is supplied to the electrode 31 during the period t 4 to t 5 , as illustrated in (5) and (6) of FIG. 2 and (2) of FIG. 3.
Sequences of pairs of the signals x(al) and x(bl) and pairs of the signals y(al) and y(bl) are applied alternatively. Accordingly, sequences of the signals V(xl) and the signals V(yl) are generated alternatively. As a result, to the spot formed by the cross point of the electode 21 and the electrode 31, a sequence of the voltage V(xy) represented by the wave form (4) of FIG. 3 is supplied. The height of the wave V(xy) is equal to the discharge sustaining voltage V s .
The base voltages of the transistors 451 through 45n are controlled when the information writing-in voltages V W , -V W are applied.
A writing-in of an information is effected by applying writing in voltages V W , -V W to the electrodes 21 and 31, respectively, as illustrated in (4) of FIG. 2 and (3) of FIG. 3. Accordingly, a consequent writing-in voltage 2V W appears in the wave form of V(xy) as illustrated in (4) of FIG. 3 during the period t13 to t14.
In the plasma display panel 1 illustrated in FIG. 1, a current of approximately 100 μA passes through a discharge occurring in a spot formed by the cross point of the electrodes. Since currents of the discharge formed in spots formed by cross points of the electrodes are supplied from the same power source, a fluctuation of the discharge sustaining voltage between the electrodes occurs if the number of the discharging spots is large because a large current must be derived from the power source. Such a fluctuation of the discharge sustaining voltage between the electrodes makes writing-in and erasing of information of a plasma display panel difficult.
The relationship between the discharge sustaining voltage and the number of discharging spots in a prior art plasma display panel is illustrated in FIG. 4. In FIG. 4, the abscissa represents the ratio Rd in percentage of the number of discharging spots to the number of the entire spots, and the ordinate represents the discharge sustaining voltage. No discharge is maintained in the region below the lower limit curve L running from p4 through p6. Excessive discharges occur in the region over the upper limit curve U running from p1 through p3. Accordingly, an appropriate discharge occurs only in the range between the curves L and U. In the prior art plasma display panel, the discharge sustaining voltage V(q2) is selected as the mean value of V(p1) and V(p4). This voltage V(q2) is constant in the range of 0% through 100% of Rd. Accordingly, the width plq4 of the margin M 0 has to be limited below a predetermined value. Sometimes it happens that no margin is obtained in the characteristic illustrated in FIG. 4. Therefore, such a characteristic as illustrated in FIG. 4 is disadvantageous for the operation of a plasma display panel.
A prior art plasma display panel providing a circuit for controlling the discharge sustaining voltage is disclosed in, for example, Japanese Patent Application Laid-open Publication No. 50-62538.
SUMMARY OF THE INVENTION
The present invention has been proposed to eliminate the above described disadvantage of the prior art plasma display panel.
It is the principal object of the present invention to enlarge the width of the margin of the discharge sustaining voltage, to prevent the reduction of the brightness of a discharging spot, and to ensure stable discharges in a plasma display panel.
In accordance with the present invention, a system for driving a plasma display panel device comprises a plasma display panel having dischargeable spots formed by cross points between X-direction electrodes and Y-direction electrodes, a drive circuit for supplying discharge sustaining voltages and information writing-in voltages to said X-directional and Y-directional electrodes and a power source for supplying power to said drive circuit, said discharge sustaining voltage being varied in accordance with the value of the discharge current through discharging spots, characterized in that said system further comprises means for dropping the output voltage of said power source, means for detecting the current supplied to said drive circuit and means for short-circuiting said output voltage dropping means, said short-circuiting means being controlled by said current detecting means, whereby predetermined different values of the discharge sustaining voltage are selected corresponding to predetermined different ranges of the ratio of the number of discharging spots to the number of the entire spots of said plasma display panel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a circuit diagram of a prior art driving circuit of a plasma display panel,
FIGS. 2 (1) to (7) and FIGS. 3 (1) to (5) illustrate a time chart of the operation of the circuit of FIG. 1,
FIG. 4 illustrates the relationship between the discharge sustaining voltage and the number of discharging spots in the device of FIG. 1,
FIG. 5 illustrates a block diagram of a system for driving a plasma display panel in accordance with an embodiment of the present invention,
FIG. 6 illustrates an example of a circuit used in the system of FIG. 5 and,
FIG. 7 illustrates the relationship between the discharge sustaining voltage and the number of discharging spots in the system of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A system for driving a plasma display panel in accordance with an embodiment of the present invention is illustrated in FIG. 5. A plasma display panel 1 is driven by a drive circuit 4 to which an electric current is supplied from a power source 8 through a voltage dropping element 6 and a current detecting element 5. A short-circuiting element 7, which is controlled by the control output signal S of the current detecting element 5, is connected the voltage dropping element 6. The input voltage of the current detecting element 5 is equal to the output voltage of the power source 8 minus the voltage drop in the voltage dropping element 6.
When the discharge current Id supplied to the drive circuit 4 is increased in accordance with the increase of discharging dots in the plasma display panel 1, such an increase of the discharge current Id is detected by the current detecting element 5 so that a control signal S is supplied to the short-circuiting (controlled shunt) element 7 which causes the voltage dropping element 6 to short-circuit. Thus, the input voltage of the current detecting element 5 and accordingly, the input voltage of the drive circuit 4, is increased due to the omission of the voltage drop in the voltage dropping element 6. Accordingly, the discharge sustaining voltage supplied to the plasma display panel 1 is increased so that a satisfactory margin is obtained in the operational characteristic of the plasma display panel 1.
An example of the operational characteristic of the plasma display panel 1 which is driven by the power supplying system of FIG. 5 is illustrated in FIG. 7. In the region where Rd is below 50%, the discharge sustaining voltage is selected as V(r5) due to the voltage drop in the voltage dropping element 6, while in the region where Rd is between 50% and 100%, the discharge sustaining voltage is selected as V(r3) which is higher by the value r3 r5 than V(r5). Thus, both the width p1 r7 of the margin M 1 and the width r2 p6 of the margin M 2 are considerably large, and accordingly, a large portion of the region between the lower limit curve L and the upper limit curve U is available for the margins M 1 and M 2 . Accordingly, the operational characteristic of the plasma display panel, is improved.
The inventor of the present invention confirmed the following facts as a result of his experiments. That is, when the number of entire spots was 200,000 and the discharge sustaining voltage V(r5) was 95 volts, the width p1 r7 of the margin M 1 was approximately 8 volts and the width r2 p6 of the margin M 2 was approximately 6 volts. It should be noted that, in the prior art characteristic illustrated in FIG. 4, the width p1 q4 of the margin M 0 was only approximately 3 volts.
An example of the circuit of the current detecting element 5, the voltage dropping element 6 and the short-circuiting element 7 is illustrated in FIG. 6. In FIG. 6, a resistor R 1 corresponds to the current detecting element, a Zener diode Z corresponds to the voltage dropping element, and the transistors Q 1 and Q 2 correspond to the short-circuiting element.
When the output current I(6) is small, the transistors Q 2 and Q 1 are in an "OFF" state, and accordingly, the output voltage V(6) equals the input voltage V(8) minus the voltage drops in the Zener diode Z and the resistor R 1 . If the output current I(6) is increased because of an increase in the discharging dots in the plasma display panel, the transistor Q 2 is turned "ON" due to the increase of the voltage across the resistor R 1 and accordingly, the transistor Q 1 is turned "ON". Thus, the current passes from the input terminal through the emitter and the collector of the transistor Q 1 and the base and the emitter of the transistor Q 2 to the output terminal. Accordingly, the voltage drop in the Zener diode is omitted and the drop in the resistor is limited to VBE of the transistor Q 2 so that the output voltage V(6) is increased.
Although in the embodiment illustrated in FIGS. 5, 6 and 7 the number of steps of the discharge sustaining voltage is selected as two in accordance with the number of regions of Rd, it is possible to divide the regions of Rd into three or more portions and accordingly, the number of steps of the discharge sustaining voltage is selected as three or more.
Furthermore, although the above described explanations are related to a plasma display panel of the AC type, the present invention is also applicable to a plasma display panel of a non-memorizing DC type which does not have the above mentioned dielectric layer on the X and Y electrodes.
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In a system for driving a plasma display panel, predetermined different values of the discharge voltage are selected corresponding to predetermined different ranges of the ratio of the number of discharging spots to the number of the entire spots of said plasma display panel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to devices and attachments for carrying articles externally upon a vehicle, and more specifically to an assembly of removably attachable devices for supporting the front, rear, and medial portions of one or more elongate articles for carriage along the side of a motor vehicle. The various devices are removably secured to the vehicle by gripping one end of each support between the hood, trunk, and/or door of the vehicle, or over a pickup truck box sidewall edge.
2. Description of the Related Art
In the course of making home repairs, remodeling, etc., the home handyman often finds it necessary to transport relatively long articles from store to home or other site where the materials will be used. Elongate materials for such projects may comprise PVC or metal pipe, plastic gutters, electrical metal tubing (EMT), wood or plastic moldings, lengths of lumber, elongate tools, etc. While a professional contractor often has a relatively large vehicle for transporting such materials as well as tools for use at the job site, the home handyman is generally restricted to using the family automobile, or perhaps a pickup truck with a relatively short bed, for transporting such elongate materials.
Various schemes have been used for transporting such materials using a conventional passenger automobile, such as passing the materials diagonally through the interior to extend from one window, tying the materials over the roof of the vehicle, etc. Such elongate article transport means are cumbersome to use, as much time must be spent in securing padding between the materials and the roof or other structure of the vehicle, and tying the materials down or otherwise securing them. Pickup trucks often do not provide any more satisfactory means of carrying such articles, as many pickups have a cargo box or bed less than eight feet in length, with some elongate materials having a length of twelve feet or more. Thus, even with a pickup truck, it is often necessary to flag the end of the load and to arrange further means for securing the load in the bed, as the tailgate must be left open.
Accordingly, a need will be seen for a means of easily securing elongate articles to the exterior of a motor vehicle, and transporting those articles securely and safely from one site to another. The present invention responds to this need by means of a series of separate hangers or attachments which removably secure to various areas of the vehicle as required. Each of the hangers comprises a flexible sheet of material which is captured between various openable and fixed components of the vehicle (hood and fender, trunk and fender, door and roof) to extend therefrom. A rigid metal support rack is removably attached to each hanger strap to support the elongate article load therein. Padding is provided between each support rack and the vehicle body.
In another embodiment, a rigid, padded hanger is provided to secure over the upper edge or lip of the cargo box of a pickup truck, with forward and/or medial hangers removably securing respectively between the hood and front fender and door and roof of the pickup, as required. In each embodiment, either two or three hangers may be used as required, depending upon the length of the materials and their rigidity or flexibility. At least the medial support may include a series of stops to provide for height adjustment thereof, as desired.
A discussion of the related art of which the present inventor is aware, and its differences and distinctions from the present invention, is provided below.
U.S. Pat. No. 1,919,271 issued on Jul. 25, 1933 to Charles K. Cady, titled “Lumber Rack,” describes a rigid, generally S-shaped hook with an upper end which is inserted between the window glass and window sill of a vehicle door. The opposite end serves as the elongate article support. Padding is placed along the contact side of the hook where it would contact the side of the vehicle door. This device is limited in its utility, as many vehicles have fixed rear windows and preclude the installation of the Cady device between the window and window sill of the vehicle body. Moreover, the removable rigid rack portion of the present invention enables it to remain secured about the elongate articles to hold them securely together while the articles are removed from the flexible portions of the carrier which remain attached to the vehicle.
U.S. Pat. No. 2,302,300 issued on Nov. 17, 1942 to William O. Davies, titled “Carrier,” describes a hook device similar to that of the Cady '271 U.S. Patent described immediately above. However, the Davies device includes a suction cup which extends inwardly to contact the outer surface of the vehicle and protect the vehicle finish. As in the case of the Cady device, the Davies device does not provide a rigid rack component which is removably attachable to a flexible hanger portion, with the hanger portion in turn being removably secured to some component of the vehicle.
U.S. Pat. No. 2,635,796 issued on Apr. 21, 1953 to Pembroke O. Davolt, titled “Parcel Tie For Automobiles,” describes a pair of flexible straps, with one end of each strap having a toggle or head attached thereto and the opposite end of each strap forming a loop through which a tiedown ring is secured. The toggle ends are captured between the hood and front fender of the vehicle, with a tiedown line being passed through each tiedown ring and secured about the article to secure it to the vehicle. Davolt does not provide any removable rigid structure for securing elongate articles thereto, as in the present elongate article carrier, nor does he provide any form of padding or protective means between his article carrier and the vehicle structure, as provided by the present invention. Moreover, Davolt does not provide any form of adjustment for his device, nor any intermediate support means, each of which is provided by the present elongate article carrier invention.
U.S. Pat. No. 4,108,342 issued on Aug. 22, 1978 to Ralph D. Riva, titled “Carrier Attachment For Automobiles,” describes a device more closely related to the device of the Davolt '796 U.S. Patent discussed immediately above, than to the present invention. The Riva device comprises a pair of components each having a plastic coated cable having a dowel or toggle at one end and a loop at the opposite end. The devices may also include a small hook for securing beneath the rain gutter of the vehicle to tie loads across the roof of the vehicle. However, the hook is much too small for use in hanging from the upper edge of a pickup truck box. The elongate articles being carried are tied by a cord to the loop of the cable; no padding is provided between the materials and the exterior finish of the vehicle. In addition, the relatively thin cable has little resistance to movement, which would allow the load to swing fore and aft to further mar the finish of the vehicle. The width of the flexible strap portions of the present article carrier components, precludes such fore and aft motion in transit.
U.S. Pat. No. 4,262,831 issued on Apr. 21, 1981 to William I. Buchanan, titled “Traffic Cone Rack For Mounting On A Vehicle,” describes a device having a rigid metal plate for bolting or other permanent attachment to the bumper or other structure of a vehicle. A cone rack formed of a rigid rod extends from the plate. No means is provided for attaching the device to a vehicle side without damaging the vehicle finish. Moreover, no flexible padded protective portion is provided by Buchanan, nor is any adjustment provided, as in the present article carrier invention.
U.S. Pat. No. 4,375,268 issued on Mar. 1, 1983 to Gordon C. Speck, titled “Automotive Vehicle Bracket,” describes a single rigid unitary component having a spaced apart pair of generally U-shaped supports connected by an elongate bar. The device is secured within a vehicle by means of a pair of clips which are wedged between the upper trim molding and headliner of the vehicle. The clips are not configured for securing between the hood or trunk and fender of the vehicle, as provided by the flexible hangers of the present elongate article carrier. Moreover, the supports of the Speck device are not removable from the connecting bar or attachment clips, whereas the article supports or holders of the present invention are removable from the flexible vehicle attachment hangers with the hangers being adjustable for spacing.
U.S. Pat. No. 4,596,348 issued on Jun. 24, 1986 to John C. Stamp, titled “Car-Mounted Carrier,” describes a device comprising a pair of flexible straps each having a bulbed end for capturing beneath the edge of the hood—fender and trunk—fender interface. The distal ends of the straps have grommets installed therein, for passing a cord or the like therethrough for tying elongate articles to the straps. The only padding means provided are separate lengths of closed cell foam material wrapped about the elongate articles, rather than being integral with the straps as in the case of the present invention. Stamp does not provide any removable rigid article support bracket, as in the present invention, and the Stamp device would appear to be subject to swaying, as in the case of the device of the Riva '342 U.S. Patent discussed further above.
U.S. Pat. No. 4,607,773 issued on Aug. 26, 1986 to Thomas A. Mason, titled “Vehicle Mounted Long Article Carrying Utility Bracket With Adjustable Cross Bar,” describes a device having a series of generally S-shaped rigid brackets. One end of each bracket secures to the vehicle structure, with the opposite end serving to support elongate articles therein, somewhat in the manner of the devices of the Cady '271 and Davies '300 U.S. Patents discussed further above. However, the vehicle attachment portions of the Mason brackets are thickly padded, and cannot be inserted between closed panels of the vehicle. The Mason brackets must be secured over a window sill of an open window, and/or over the edge of an open trunk lid, whereas the present article carrier includes relatively wide but thin and flexible straps which easily fit between closed panels (trunk, hood, door) of the vehicle. Moreover, the hangers of the Mason device are interconnected, whereas the present hangers are independent of one another, relying only upon the vehicle structure for spacing and positioning.
U.S. Pat. No. 4,942,989 issued on Jul. 24, 1990 to Kevin W. Miller, titled “Device For Carrying Lumber And The Like, ” describes a pair of rigid brackets including padding on the vehicle contact portions thereof, somewhat like the device of the Mason '773 U.S. Patent discussed above. The same limitations noted for the Mason device are seen to apply here, with the Miller device being too thick to secure between panels of the vehicle structure and requiring the windows to be rolled down for use. The present invention does not have such limitations, due to the thin hangers.
U.S. Pat. No. 5,029,785 issued on Jul. 9, 1991 to James A. Besong, Jr., titled “Car Mounted Article Carrying Bracket,” describes a system having a pair of separate, rigid components which secure to the vehicle between the hood and trunk and their respective fenders. A pair of padded feet extends from each component to brace against the vehicle structure. The footpads are relatively small in comparison to the cushioned area of the present article carrier, and could distort the underlying sheet metal in the event that relatively heavy loads are carried by the Besong, Jr. device. Moreover, each of the Besong, Jr. devices is essentially unitary (with adjustable components), with no separable support bracket and hanger strap, as in the present article carrier. It is also noted that the bottom support surface of the Besong, Jr. brackets are essentially level with the upper fender line, with the forward bracket and/or materials carried therein interfering with the right side exterior mirror. This is not a problem with the present article carrier, which depends below the fender line to carry any articles relatively low on the vehicle.
Finally, Japanese Patent Publication No. 11-099,963 published on Apr. 13, 1999 to Mazda Motor Corporation illustrates a vehicle having an open rear portion with various attachments being provided therefor. None of the attachments is adapted for the carriage of elongate articles along the side of the vehicle, as provided by the present invention.
None of the above inventions and patents, either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
The present invention comprises an elongate article carrier for vehicles, for the external carriage of such articles as garden tools, fishing poles, lumber, PVC and EMT tubing and pipe, etc. upon an automobile, pickup truck, or the like. The present article carrier obviates the need for carrying such elongate articles within the vehicle interior (or cargo bed of a pickup), thus simplifying the loading of the vehicle and precluding any need for flags or the like to be attached to the distal ends of the articles. As all elongate articles are carried upon the vehicle exterior, windows and doors may remain closed in inclement weather.
The present invention comprises at least two thin, flexible, wide, elongate straps or bands. Each strap has a vehicle attachment end and a cargo securing portion extending therefrom. The vehicle attachment end may comprise one or more protuberances imbedded therein, for capturing within the trunk, engine compartment, and/or passenger compartment of the vehicle. The appropriate panel (door, hood, trunk) of the vehicle is opened, the attachment end and protuberance are placed within the compartment, and the panel is closed to capture the thicker protuberance within the compartment. The opposite cargo securing portion includes a tab for the removable attachment of a rigid hanger therefrom, with the hanger supporting elongate articles placed therein. A padded area extends below the hanger attachment tab to preclude damage to the vehicle finish. An alternative embodiment comprising a rigid bracket is used to attach an article carrier to the side of a pickup truck box.
Accordingly, it is a principal object of the invention to provide an improved elongate article carrier for vehicles, comprising at least two thin, flexible, wide, elongate straps or bands removably attachable to the exterior of a motor vehicle, with each of the straps or bands having a rigid article support hanger removably depending therefrom.
It is another object of the invention to provide an improved elongate article carrier which straps each have an attachment end which may include one or more protuberances therein, for capturing within the engine, trunk, or passenger compartment of the vehicle by closing the appropriate panel upon the strap to capture the protuberance therein.
It is a further object of the invention to provide an improved elongate article carrier having an adjustable length by means of a plurality of protuberances disposed within the attachment end thereof.
An additional object of the invention is to provide an improved article carrier for removable installation to the side wall of the box of a pickup truck, with the article carrier including a rigid bracket therein for hooking over the box side wall.
Still another object of the invention is to provide an improved article carrier including cushioning or padding means disposed between the rigid article support hanger and the surface of the vehicle, thereby precluding damage to the vehicle.
It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental perspective view showing the present elongate article carrier installed upon a passenger vehicle.
FIG. 2 is an environmental perspective view of an alternate embodiment, showing an article carrier strap for removable installation upon the side wall of a pickup truck box.
FIG. 3 is a detailed perspective view of a hood or trunk article carrier assembly, showing various details thereof and the removable attachment of the hanger bracket thereto.
FIG. 4 is a detailed perspective view of an article carrier strap for removable installation in the door of a vehicle, showing installation and other details thereof.
FIG. 5 is a broken away detailed perspective view of the pickup box side wall attachment embodiment of FIG. 2, showing further details thereof.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention comprises an apparatus for carrying elongate articles externally along the side of a motor vehicle, thus obviating need for carrying the articles within the interior of the vehicle with one end of such articles projecting from an open window. FIG. 1 illustrates a first embodiment of the present invention, comprising a series of elongate article carriers 10 and 12 removably secured to various panels of the vehicle V. The conventional motor vehicle V includes various openable and adjacent fixed panels, including an openable hood H with a closely fitting front fender FF to each side or edge thereof, with a trunk lid T and closely fitting rear fenders RF to each side thereof. At least one door D is provided on each side of the vehicle V, with the upper frame or edge of the door D fitting closely with the roof R of the vehicle V, generally as shown in FIG. 1. A third embodiment 14 is illustrated in FIG. 2, for securing over the upper edge of the sidewall S of the cargo box of a pickup truck P.
The embodiments 10 and 12 make advantageous use of the slight gaps or clearances provided between the various openable panels and their adjacent relatively fixed components of the vehicle V. The upper ends of the present article carriers 10 and 12 may be captured between various openable and fixed components of the vehicle V, thus anchoring the carriers 10 and 12 securely to the vehicle V as desired. The carriers 10 and 12 each include a rigid article support hanger 16 removably secured thereto, for carrying and supporting elongate articles A therein.
FIG. 3 provides a detailed illustration of a first embodiment article carrier 10 , as shown installed in the forward and rearward positions on the vehicle V of FIG. 1 . The article carrier 10 is essentially constructed of two plies or layers 18 a and 18 b of a flexible fabric or other suitable material to form a wide, thin, and flexible elongate strap 20 . The strap 20 may be formed by folding a single sheet of material over along one edge, and securing the two folded plies along all edges by means of stitching 22 or other suitable means.
The strap 20 includes a vehicle attachment end 24 , with an article support hanger attachment portion 26 depending from the attachment end 24 . The strap 20 is gathered at a point below the attachment end 24 to form the hanger attachment portion or tab 26 extending across the width of the strap 20 , with stitching 28 used to secure the tab 26 . This results in four plies of material to provide an extremely strong and durable attachment area for the article hanger 16 . A pair of grommets 30 are installed through the hanger attachment portion or tab 26 , to provide for the removable attachment of the article hanger 16 to the strap 20 .
The article support hanger 16 is preferably formed from a length of metal rod. The rod is bent in the center to form two ends, with the continuous intermediate portion of the rod bent to form an outward and upward, generally squared U-shaped support area 32 . The ends are bent to form first and second fingers or hooks 34 , which are used to removably engage the grommets 30 of the hanger attachment tab 26 of the strap 20 , as shown in FIG. 3 .
The double layer of material used to form the present article carrier embodiments provides advantages in addition to the greater strength provided by two layers of material. The two layers 18 a and 18 b may be used to enclose other components, as shown in the vehicle attachment end portion 24 of the device 10 of FIG. 3 . The double layers 18 a and 18 b are used to form a pocket in the upper or vehicle attachment end 24 of the carrier 10 , into which a relatively thick component (length of PVC tubing or pipe, wood or plastic dowel, etc.) is inserted. The end of the pocket is then sewn shut during the final assembly of the carrier 10 , to form a protuberance 36 in the vehicle attachment end 24 of the device.
This relatively thick protuberance 36 is thicker than the gap between any of the fixed and openable components (hood/fender, trunk/fender, etc.) of a conventional motor vehicle, and thus cannot pass through such a gap when the hood, trunk, etc. is closed with the strap portion 20 placed within the gap. The protuberance 36 , and thus the vehicle attachment end 24 , of the carrier device 10 is captured within the closed compartment (trunk, engine compartment, etc.) of the automobile, thus locking the carrier 10 securely to the vehicle during the time the compartment remains closed, generally as shown in FIG. 1 of the drawings. The carrier 10 is easily removed from the vehicle as desired, merely by unlocking the trunk or opening the hood.
The opposite lower portion 38 of the carrier device 10 includes padding or cushioning means therein, as shown in the carrier device 14 embodiment of FIG. 5 . In this respect, all of the various carrier embodiments 10 , 12 , and 14 are essentially identical, and details of the padding means 40 will be understood to apply to the embodiments 10 and 12 of FIGS. 1 through 4 as well as to the embodiment 14 of FIGS. 2 and 5. The double thickness of material used to construct the present elongate article carriers 10 through 14 provides a pocket for the installation of padding or cushioning means therein, with details of such padding or cushioning means being discussed further below. The padding or cushioning means will be seen to be disposed between the body of the vehicle and the support hanger 16 when the article carrier 10 through 14 is secured to the vehicle, as shown in FIGS. 1 and 2.
To this point, only a first embodiment article carrier 10 has been discussed in detail. This single embodiment works well for use with a conventional passenger vehicle V as shown in FIG. 1 of the drawings, as an identical carrier 10 may be removably installed between the hood H and front fender FF and between the trunk lid T and rear fender RF of the vehicle V. However, in many instances the elongate articles A being carried are relatively flexible (e.g., relatively thin PVC pipe or tube, relatively small thicknesses of quarter round or other molding, etc.), and should be supported along their central area as well as at each end.
Accordingly, a second embodiment 12 of the present elongate article carrier provides for removable installation between the upper frame of the door D and the roof R of the vehicle, as shown in FIGS. 1 and 4. (An identical carrier 12 is also shown installed to the door D of the pickup truck P of FIG. 2.) The second embodiment carrier 12 has a somewhat similar configuration to that of the first embodiment carrier 10 , comprising two layers of fabric 48 a and 48 b to form a strap 50 secured by stitching 52 .
The strap 50 includes a vehicle attachment end 54 , as in the attachment end 24 of the carrier embodiment 10 of FIGS. 1 through 3. However, the end 54 of the carrier 12 of FIG. 4 differs from its equivalent component of the carrier 10 of FIGS. 1 through 3, in that the attachment end 54 of the article carrier 12 is considerably longer. A series of pockets 62 are formed in the elongate vehicle attachment portion 54 of the carrier 12 , with a relatively thick component 64 (pipe, rod, etc.) being inserted into each pocket 62 before the final stitching 52 is done along the otherwise open edge of the device. Completion of the stitching 52 results in a series of spaced apart protuberances 66 along the vehicle attachment portion 54 of the carrier 12 , thus providing for adjustment of the height of the carrier 12 . A user of the present invention need only install a carrier 10 at the front and rear of the vehicle, then install a carrier 12 by aligning the hanger attachment tab 56 or hanger 16 attached thereto with corresponding components of the forward and rearward carriers 10 , and close the door D upon the vehicle attachment portion 54 of the carrier 12 .
The remainder of the article carrier 12 of FIGS. 1, 2 , and 4 is essentially identical to the corresponding components of the carrier 10 of FIGS. 1 through 3, having a pair of grommets 60 installed through the hanger attachment tab or portion 56 to provide for the removable attachment of a rigid article support hanger 16 , which hanger 16 is identical for all embodiments. The lower portion 68 of the carrier embodiment 12 is also thickly padded in order to preclude damage to the door D of the vehicle, as in the padded area 38 of the article carrier embodiment 10 . It should be noted that the article carrier 14 is placed well to the rearward edge of the door D, as is clearly shown in FIGS. 1 and 2 of the drawings. Thus, the lateral area which might be blocked by the carrier 12 is positioned at the very edge of the peripheral vision of the driver of the vehicle V or pickup truck P, and closely matches the area of the central or “B” pillar of the vehicle. The right side exterior mirror is completely visible to the driver using the present article carrier invention, and any articles A carried therein are positioned below the side windows of the vehicle V or pickup P to provide a clear field of view, as is clearly shown in FIGS. 1 and 2 of the drawings.
FIG. 2 illustrates the removable installation of one carrier of each of the three embodiments 10 through 14 of the present invention on a pickup truck P. A first embodiment article carrier 10 is installed with its vehicle attachment portion captured between the hood and front fender of the pickup truck P, in the manner shown for the forwardly installed carrier 10 of FIG. 1 .
A central, second embodiment carrier 12 is installed with its vehicle attachment portion 54 gripped between the upper edge of the door D and the roof R of the pickup truck P. This installation of the first and second embodiment article carriers 10 and 12 respectively at the hood to front fender and door to roof seams, will be seen to be identical with the installation of those components illustrated in FIG. 1 of the drawings.
However, a third embodiment article carrier 14 includes a different attachment end or portion for securing removably over the upper edge of the side wall S of the cargo box of the pickup truck P, as shown in FIG. 2 of the drawings. FIG. 5 provides a detailed view of this embodiment 14 , as well as a disclosure of the padding means used in the lower portions of each of the embodiments of the present invention. The article carrier 14 is constructed similarly to the article carriers 10 and 12 , being formed of a folded over sheet of fabric material to form a relatively wide strap 80 formed of two plies or sheets 78 a and 78 b joined by edge stitching 82 . The strap 80 includes a vehicle attachment end 84 , as in the other two embodiments 10 and 12 of the present invention. However, the attachment end 84 differs from those of the first two embodiments 10 and 12 , comprising a rigid, generally squared off U-shaped bracket 92 which is captured between the two sheets 78 a and 78 b. The bracket 92 is configured to hang or secure over the upper edge of a pickup truck box side wall S, as shown in FIGS. 2 and 5. The inner panel 94 of the bracket 92 may be bent slightly toward the outer panel 96 , to provide positive grip for the device 14 .
The remainder of the device is essentially the same as those equivalent components of the carrier embodiments 10 and 12 , having a hanger attachment tab 86 formed by stitching 88 , grommets 90 (only one of which is shown in the broken away view of FIG. 5 ), and padded lower portion 98 . The article carrier 14 is installed upon the upper edge of the cargo box side wall S by bending the two facing panels 94 and 96 slightly apart and lowering the attachment end 84 of the article carrier 14 over the upper edge of the cargo box side wall S, with the bracket or plate 92 gripping the side wall S between the two facing panels 94 and 96 of the plate or bracket 92 .
FIG. 5 also illustrates details of the lower padded area 98 of the article carrier embodiment 14 , which will be understood to be identical to the padding or cushioning means provided for the other carrier embodiments 10 and 12 . As noted above, each of the embodiments of the present article carrier is formed of a folded over sheet of material, resulting in two plies or layers, e.g., the first and second plies 78 a and 78 b of the article carrier 14 of FIG. 5 . Just as the two plies of the upper portion of the carrier 14 were used to form a pocket for the bracket or plate 92 , these two plies are also used to provide a pocket 100 for placement of resilient cushioning material 102 therein. A flexible, moistureproof bag or container 104 is used to contain the resilient material to preclude moisture absorption and potential problems resulting therefrom, with the container 104 being sewn between the two plies of the lower portion of the device during final stitching.
The present elongate article carrier invention is used essentially as illustrated in FIGS. 1 and 2 of the drawings, with a carrier first embodiment 10 being captured between the hood H and front fender FF and trunk lid T and rear fender RF of a passenger vehicle V. A central carrier 12 may be installed between the upper edge of the passenger door D and the roof R of the vehicle V, if required or desired. Support hangers or racks 16 are installed in at least the forward and rearward article carriers, with such a hanger 16 optionally installed with the central carrier 12 as well. Alternatively, a bungee cord C may be wrapped about the central portion of the elongate article A bundle, and hooked to the grommets of the central article carrier 12 .
In FIG. 2, a first embodiment carrier 10 is secured at the hood and front fender of the pickup truck P, with a second embodiment carrier 12 secured between the upper rearward portion of the door D and adjacent roof R. A third embodiment carrier 14 is secured over the upper edge of the pickup truck box side wall S. Each of the article carriers 10 through 14 has a support hanger 16 secured thereto, with a series of elongate articles A resting therein. The elongate articles A are secured in place within the support hangers, and thus to the article carriers and vehicle to which the carriers are secured, by means of a series of bungee cords C or the like which are wrapped about the articles at each carrier and hooked to the corresponding rigid support hanger 16 . The resulting arrangement provides a very secure means of hauling elongate articles with a conventional passenger car or pickup truck.
In summary, the present elongate article carrier invention provides a much needed means of transporting elongate articles such as lumber, pipe and tubing, garden tools, gutters, fence components, etc. from one site to another, without requiring awkward placement partially within and partially outside the vehicle, or the flagging of long rearwardly trailing extensions, etc. The article carriers of the present invention are extremely easy to install upon the vehicle, merely by opening the hood and trunk and gripping the protuberance area of the carrier within the compartment after closing the hood or trunk panel. The medial carrier is used in the same manner, by gripping it between the door frame and roof of the vehicle. The forward and medial carriers are used in exactly the same manner for use with pickup trucks, but an alternative embodiment carrier is hooked over the upper edge of the pickup box side wall to serve as the rearward carrier. A rigid support hanger or rack is then hooked to each article carrier, the elongate materials placed within the hangers, and secured within the hangers by bungee cords or other suitable means.
As noted further above, the strap portions of the present elongate article carriers are relatively wide. This provides a significant benefit, in that such wide straps are not prone to swing laterally relative to their attachment to the vehicle (i.e., longitudinally in the direction of vehicle travel) due to acceleration and deceleration, wind loads, etc. This provides further stability for the load being carried by means of the present elongate article carrier invention.
Upon reaching the destination, the article carriers are easily removed from their attachment points on the vehicle by opening the appropriate compartments (hood, door, trunk) and lowering the bundle of elongate articles to the underlying surface. The article carrier used with a pickup box side wall is merely lifted from the side wall to remove the device from the truck. The article carriers may be left in place on the bundle of articles, if so desired, in order to provide further ease of carrying the bundle.
Alternatively, the support hangers may be unhooked from their positions on their respective article carriers, with the elongate articles remaining secured therein by means of the bungee cord attachments. Once the bundle of articles has been placed as desired, the bungee cords may be removed from the support hangers, and the article carrier strap portions rolled or folded to provide for compact storage of the assembly until needed again. Accordingly, the present elongate article carrier embodiments will prove to be a most desirable accessory for general contractors, home handymen, and others who have occasion to carry various elongate articles using a conventional passenger car, pickup truck, or the like.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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An elongate article carrier for use with motor vehicles provides at least two separate wide, thin, flexible, elongate straps or bands, each of which in turn supports a rigid article support hanger which is removably secured to the band. Each of the bands includes a vehicle attachment end and a hanger attachment tab or portion extending therefrom. In one embodiment, the bands each have one or more protuberances captured in the vehicle attachment end, with the protuberance(s) providing for the removable attachment of each band to the vehicle. A panel (door, hood, or trunk) of the vehicle is opened, the protuberance is placed within the opened compartment, and the panel is closed to capture the protuberance within the compartment and preclude slippage of the band from the vehicle so long as the compartment remains closed. A plurality of such protuberances in a single band provides for height adjustment of the band, if so desired. An alternative embodiment includes a rigid bracket for removably securing to the upper lip of the side wall of a pickup truck box, for using such a vehicle as an elongate article carrier. Each of the article carrier band embodiments further includes a padded or cushioned area depending from the hanger attachment tab and sandwiched between the rigid article support hanger and the vehicle structure, thereby protecting the finish of the vehicle during use of the present invention.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. § 119(a) of a Korean Patent Applications Nos. 10-2009-0126242, filed on Dec. 17, 2009, and 10-2010-0036024, filed on Apr. 19, 2010, the entire disclosures of which are incorporated herein by reference for all purposes.
BACKGROUND
[0002] 1. Field
[0003] The following description relates to a phase modulation technique, and more particularly, to a phase modulation apparatus and method which reflects a communication mode to apply a variable specification.
[0004] 2. Description of the Related Art
[0005] A variable bandwidth Phase Locked Loop (PLL) is applied to a phase modulation apparatus which is generally used in a communication apparatus. Phase modulation using a variable bandwidth PLL has advantages of low cost, low power consumption, excellent noise characteristics, high modulation precision, etc.
[0006] In order to achieve high modulation precision, a PLL has to have a wider frequency bandwidth than that of a modulation signal. This is because a high reference frequency reduces a division ratio N to widen the bandwidth of a loop filter and also shorten a PLL lock time. However, a wide bandwidth of PLL degrades noise characteristics.
[0007] In order to solve the problem, a 2-point modulation method has been proposed which sets a modulation bandwidth of a PLL to be narrower than a modulation bandwidth and performs modulation within a PLL band and modulation outside of a variable PLL band at two different points.
[0008] According to the 2-point modulation method, since no control signal is transferred to a loop filter when a communication mode is a narrow-band mode, effectively only a 1-point modulation is performed. When the communication mode is a wide-band mode, control signals are transferred to individual communication apparatuses to modulate signals outside of the PLL band.
[0009] With development of cognitive access techniques and software defined radios (SDR) terminals, demands for a communication apparatus capable of supporting multiple modes are increasing, however, existing phase modulation techniques have limitations in satisfying these demands.
SUMMARY
[0010] The following description relates to a phase modulation apparatus and method that can perform phase modulation adaptively depending on a communication mode.
[0011] In one general aspect, there is provided a phase modulation apparatus including: a storage to store phase modulation setting values corresponding to various communication modes; a phase modulation setting value selector to select, when a communication mode is changed, phase modulation setting values corresponding to the changed communication mode among the phase modulation setting values stored in the storage; and a phase modulator to modulate a phase of a transmission signal using the phase modulation setting values selected by the phase modulation setting value selector. The phase modulation setting values include at least one of a reference frequency, a division ratio and a modulation bandwidth value.
[0012] In one general aspect, there is provided a phase modulation method including: deciding, when a communication mode is changed, phase modulation setting values using pre-stored information; and performing phase modulation according to the decided phase modulation setting values. The phase modulation setting values include at least one of a reference frequency, a division ratio and a modulation bandwidth value.
[0013] Accordingly, the frequency characteristics of a loop filter in a Phase Locked Loop (PLL) change depending on a transmission mode of a communication apparatus and an appropriate bandwidth is used according to a transmission modes to perform phase modulation, thereby preventing noise characteristics from degrading when the bandwidth of the PLL changes.
[0014] Also, since a reference frequency of a PLL can be changed and a division ratio can be automatically changed, a phase modulation apparatus and a data transmission apparatus is to which various communication specifications can be applied are implemented.
[0015] Furthermore, since the frequency response, reference frequency and division ratio of the loop filter in the PLL can be set to appropriate values automatically according to a transmission mode, load to other circuits can be reduced. In addition, since an appropriate PLL band of a phase modulation bandwidth can be selected according to a communication mode, noise out of the PLL band is reduced and noise characteristics are improved, which leads to performance improvement of a communication apparatus.
[0016] Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a diagram illustrating an example of a phase modulation apparatus.
[0018] FIG. 2 is an example of a reference table that is used to decide a voltage signal for controlling a loop filter in the phase modulation apparatus illustrated in FIG. 1 .
[0019] FIG. 3 is a characteristic graph showing the relationship between a modulation bandwidth and a PLL bandwidth.
[0020] FIG. 4 is a circuit diagram illustrating an example of a loop filter.
[0021] FIG. 5 is a flowchart illustrating an example of a phase modulation method.
[0022] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.
DETAILED DESCRIPTION
[0023] The following description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses, and/or systems described herein. Accordingly, various changes, modifications, and equivalents of the methods, apparatuses, and/or systems described herein will be suggested to those of ordinary skill in the art. Also, descriptions of well-known functions and constructions may be omitted for increased clarity and conciseness.
[0024] FIG. 1 is a diagram illustrating an example of a phase modulation apparatus.
[0025] Referring to FIG. 1 , the phase modulation apparatus includes: a phase modulator 120 , a storage 100 , a phase modulation setting value selector 110 , a switching unit 130 , a filter 132 , a digital-to-analog converter 134 and a modulation signal generator 136 . The phase modulator 120 includes a reference frequency oscillator 122 , a phase comparator 126 , a loop filter 128 , a voltage-controlled oscillator 129 and a frequency divider 124 .
[0026] The phase modulation apparatus has to determine an appropriate reference frequency, an appropriate division ratio (N) and an appropriate loop bandwidth when a communication mode changes.
[0027] Conventionally, in the case of a single or multi mode, a reference frequency and a division ratio are both fixed or only a division ratio is changeable. However, a communication apparatus capable of supporting various communication modes, which is to be developed in the future, has to be able to change both a reference frequency and a division ratio. Optimal values of the reference frequency and division ratio may be predetermined.
[0028] The storage 100 may be a memory, and stores an optimized reference frequency, division ratio and loop bandwidth with respect to various communication modes, in the form of a table.
[0029] According to an example, the phase modulation setting value selector 110 decides a is modulation bandwidth according to a communication mode based on stored information, and outputs a voltage signal for controlling the loop filter 128 to change a PLL bandwidth. For example, the phase modulation setting value selector 110 decides a reference frequency, a division ratio and a modulation bandwidth, with reference to the table that is stored in the storage 100 and includes information about reference frequencies, division ratios (N) and modulation bandwidths with respect to communication modes. Then, the phase modulation setting value selector 10 transfers the decided reference frequency, division ratio and modulation width to the reference frequency oscillator 122 , the frequency divider 124 , the switching unit 130 and the loop filter 128 . Accordingly, depending on a communication mode, the switching unit 130 is turned on or off to perform 1-point modulation or 2-point modulation, so that a reference frequency, a division ratio and a bandwidth of a PLL circuit are changed. Also, the frequency response of the loop filter 128 is changed.
[0030] The phase modulation setting value selector 110 outputs, when the modulation bandwidth is set to a narrow-band mode with reference to the table that includes modulation bandwidths with respect to communication modes, a control signal for turning off the switching unit 130 . If the switching unit 130 is turned off, 1-point modulation is performed so as not to perform the modulation out of the PLL band. Then, the phase modulation setting value selector 110 outputs voltage signals V t1 and V t2 to be input to the loop filter 128 , the voltage signals V t1 and V t2 decided according to the decided modulation bandwidth. In the phase modulation apparatus, since the frequency of the loop filter 128 is lowered when the communication mode is a narrow-band mode, a resonance point of the frequency of the loop filter 128 with resistance is lowered to make a bandwidth narrow.
[0031] Meanwhile, the phase modulation setting value selector 110 transfers a control signal to the switching unit 130 with reference to the table that includes modulation bandwidths with respect to communication modes, thus turning on the switching unit 130 . If the switching unit 130 is turned on, 2-point modulation is performed to perform the modulation out of the PLL band.
[0032] Also, the phase modulation setting value selector 110 outputs voltage signals V t1 and V t2 to be input to the loop filter 128 , the voltage signals V t1 and V t2 decided according to the decided modulation bandwidth. When the communication mode is a wide-band mode, the frequency of the loop filter 120 is raised and a resonance point of the frequency of the loop filter 128 with resistance is accordingly raised, resulting in an increase of a bandwidth.
[0033] FIG. 2 is an example of a reference table that is used to decide a voltage signal for controlling the loop filter 128 in the phase modulation apparatus illustrated in FIG. 1 .
[0034] Referring to FIGS. 1 and 2 , the phase modulation setting value selector 110 may decide a voltage signal for controlling the loop filter 128 appropriately according to a communication mode, with reference to predetermined table information seen in FIG. 2 . According to an example, the reference table, which is constructed according to a general PLL design procedure, is made in various forms depending on applications.
[0035] FIG. 3 is a characteristic graph showing the relationship between a modulation bandwidth and a PLL bandwidth.
[0036] As seen in FIG. 3 , if a PLL band 1 denoted in a solid line is narrowed, its bandwidth H(s) is also narrowed. However, the bandwidth H(s) of the PLL band 1 is still wider than a transmission bandwidth of a communication mode 1 which is a narrow-band mode. By preventing an output signal from being positioned outside a modulation band of a modulation signal, it is possible to reduce degradation of modulation precision and suppress power consumption.
[0037] Meanwhile, referring to FIGS. 1 and 3 , when the communication mode 1 is a wide-band mode, the frequency of the loop filter 128 is raised due to input voltage signals V t1 and V t2 of the loop filter 128 which are decided by the phase modulation setting value selector 110 , and a resonance point of the frequency of the loop filter 128 with resistance is also raised, which increases a bandwidth.
[0038] As seen in FIG. 3 , the bandwidth of a PLL circuit is widened from the PLL band 1 to a PLL band 2 .
[0039] In a wide-band modulation mode, when the switching unit 130 is controlled to be turned on, 2-point modulation is performed, a resonance point of the loop filter 128 is changed and a PLL bandwidth H(s) is wider than in a narrow-band mode. Also, if a communication mode bandwidth is further widened when 2-point modulation is performed, the resonance point of the frequency of the loop filter 128 with resistance is further raised due to the input voltage signals V t1 and V t2 of the loop filter 128 , which are decided according to a modulation bandwidth.
[0040] Accordingly, as seen in FIG. 3 , the bandwidth of the PLL circuit is widened from the PLL band 2 to a PLL band N.
[0041] In other words, in the wide-band modulation mode, by varying the resistance value of the loop filter 128 , it is possible to reduce the outer region of the PLL band. Accordingly, characteristic degradation due to sensitivity and linearity of a voltage-controlled oscillator (VCO) may be reduced. In addition, the VCO may be allocated a noise margin, which relieves a design specification.
[0042] FIG. 4 is a circuit diagram illustrating an example of a loop filter. As illustrated in FIG. 4 , the loop filter may be implemented with various configurations that use variable resistors and variable capacitors to change a PLL bandwidth in order to support various communication modes. A plurality of pin diodes pd 1 , . . . , pdM is are arranged to implement variable resistance to thus widen a variable range of resistance. Also, a varactor diode vd 1 may be provided to form a variable capacitor. However, the configuration of the loop filter is not limited to this.
[0043] FIG. 5 is a flowchart illustrating an example of a phase modulation method.
[0044] A phase modulation apparatus decides, when determining that a communication mode has been changed (operation 500 ), phase modulation setting values according to the changed communication mode (operation 510 ). At this time, the phase modulation apparatus has to decide an appropriate reference frequency, division ratio (N) and loop bandwidth according to the changed communication mode. The phase modulation setting values are decided with reference to a pre-stored table. Then, the phase modulation setting values are applied to a phase modulator (operation 520 ).
[0045] In detail, application of the phase modulation setting values is to provide reference frequency information to a reference frequency oscillator, a division ratio value to a s frequency divider, filter bandwidth information to a loop filter and an on/off control signal to a switching unit.
[0046] According to an example, when a modulation bandwidth is set to a narrow-band mode with reference to a table that includes modulation bandwidths with respect to communication modes, a control signal for turning off the switching unit is output. If the switching unit 130 is tuned off, 1-point modulation is performed so as not to perform the modulation out of a PLL band.
[0047] Then, voltage signals V t1 and V t2 to be input to the loop filter are output according to the set modulation bandwidth. In the phase modulation apparatus, since the frequency of the loop filter 128 is lowered when the communication mode is a narrow-band mode, a is resonance point of the frequency of the loop filter with resistance is lowered to make a bandwidth narrow.
[0048] A phase modulator may perform phase modulation based on the phase modulation setting values (operation 530 ).
[0049] The processes, functions, methods and/or software described above may be recorded, stored, or fixed in one or more computer-readable storage media that includes program instructions to be implemented by a computer to cause a processor to execute or perform the program instructions. The storage includes magnetic media, optical media and the like.
[0050] A number of examples have been described above. Nevertheless, it will be understood that various modifications may be made. For example, suitable results may be achieved if the described techniques are performed in a different order and/or if components in a described system, architecture, device, or circuit are combined in a different manner and/or replaced or supplemented by other components or their equivalents. Accordingly, other implementations are within the scope of the following claims.
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A phase modulation apparatus and method are provided. The phase modulation apparatus includes a storage to store phase modulation setting values corresponding to various communication modes; a phase modulation setting value selector to select, when a communication mode is changed, phase modulation setting values corresponding to the changed communication mode among the phase modulation setting values stored in the storage; and a phase modulator to modulate a phase of a transmission signal using the phase modulation setting values selected by the phase modulation setting value selector. According to the phase modulation apparatus, since a frequency characteristic of a loop filter in a PLL circuit is changed depending on a transmission mode of a communication apparatus and phase modulation is performed using appropriate bandwidths according to various transmission modes, it is possible to prevent noise characteristics from degrading when a PLL bandwidth changes.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for forming a film by selective area growth by MOCVD using a dielectric mask, in particular a method for controlling a growth rate in growing a semiconductor optical waveguide structure.
2. Discussion of Background
The selective area growth using metal organic chemical vapor deposition (MOCVD); a dielectric mask utilizes an effect that a growth rate increases at an edge and a peripheral portion of the mask. This effect occurs because growth species reaching the mask diffuse in the vapor phase or on the mask surface toward the peripheral portion of the mask to a semiconductor substrate.
In FIGS. 8(a) and 8(b), there are shown a top plan view and a cross-sectional view of a conventional mask. In these Figures, reference numeral 1 designates a mask, and reference numeral 2 designates an opening in the mask. In the; fabrication of a conventional practical device, two mask elements having a width Wm are spaced Wo apart as shown in FIG 8a), and the growth rate increasing effect at a region (a region of the space Wo) sandwiched between the mask elements 1, i.e. the opening 2, is utilized. The growth rate at the region increases in proportion to the mask width Wm, and further increases when the mask space Wo gets narrower. Accordingly, the presence of a difference in growth rate between a peripheral portion of the mask 1 and the opening 2 at the region sandwiched by the mask pieces 1, and regions remote from the mask 1 enables the mask 1 to control the distribution of the thickness of a layer grown on an upper surface of the substrate.
In the past, various kinds of optical devices have been produced using such a principle. Because the mask 1 which has been formed once can not be removed or changed in terms of width or space until completion of the growth process, the growth rate during growth is one which has a constant increase rate which is determined by the width and the opening of the formed mask 1.
For example, when the conventional technique is applied to fabrication of an optical waveguide device, such as a semiconductor laser with an optical waveguide modulator, selective growth is made in the order of a lower cladding layer, a multiple-quantum well structure (MQW) waveguide layer, an upper cladding layer, and a contacting layer at the opening 2 as shown in the sectional view of FIG. 8(c), and all semiconductor layers have a constant increase in growth rate. At a region remote from the mask 1, growth is made at a normal growth rate. As a result, the band gap difference in; the waveguide layer occurs due to a change in layer thickness in an MQW structure between a region remote from the mask 1 and the opening 2, and two functional elements of the semiconductor laser and the optical waveguide modulator are simultaneously fabricated. In FIG. 8(d), there is shown a view of a change in growth rate with respect to growth time at the conventional mask opening 2. In this figure, R g refers to the growth rate at an arbitrary point in a peripheral portion of the mask, and R 0 refers to the growth rate at an arbitrary point quite away from the mask. This figure shows that the increase in growth rate is constant throughout the growth time in using the conventional mask 1.
The conventional selective area growth using MOCVD has a disadvantage in that layer thickness is increased even in a layer having no need for the layer thickness increasing effect because the growth rate increase at the opening 2 is constant during the growth of all semiconductor layers which are grown using the same mask. For example, in order to obtain necessary functions in two elements of the semiconductor laser and the optical waveguide modulator, it is enough for a change in layer thickness to occur only in the MQW structure, and an increase in layer thickness is not necessary in other semiconductor layers. In particular, an increase in layer thickness of the upper and lower cladding layers, which have a greater layer thickness than the waveguide layer, is the primary cause of a difference in layer thickness between the region remote from the mask 1 and in the opening 2. This creates nonuniformity in layer thickness on a substrate surface, which contributes to a decrease in yield in subsequent processes, e.g. nonuniformity in deposition in a resist deposition process.
SUMMARY OF THE INVENTION
It is an object of the present invention to solve the problem as stated above, and to provide a method for forming a film by selective area growth of MOCVD, controlling an increase in growth rate for every structural layer during collectively selective area growth of layers of a semiconductor optical waveguide structure or the like.
The foregoing and other objects of the present invention have been attained by providing a method for forming a film by selective area growth of MOCVD technique, which includes the steps of forming a mask on a semiconductor substrate having a (100) plane as a typical plane, the mask having a mask opening to selectively grow a compound semiconductor layer, and a slit which is narrower than the mask opening in width and controls a growth rate of the compound semiconductor layer at the mask opening; and selectively growing the compound semiconductor layer at a growth rate which is higher than that at a region quite away from the mask on the semiconductor substrate and which is lower than that in the case of a slitless mask, by reevaporating or diffusing growth species of the compound semiconductor layer on the mask to oversupply the growth species onto the mask opening and the slit.
It is preferable that the mask opening and the slit are arranged in parallel with a (011) crystal plane direction of the semiconductor substrate.
It is preferable that the method includes a step of utilizing a phenomenon that the growth species of the compound semiconductor layer forms a non-growth surface of a (111) B plane while maintaining a constant sharp angle at a portion in contact with a mask edge, and that the growth species self-stops growing when the growth species have had an isosceles triangle of cross-section, wherein after self-stop of growth, the compound semiconductor layer is selectively grown at the mask opening at a growth rate which is the same as the slitless mask.
It is preferable that the method includes a step of using a Group III organometallic source material and a Group V source material as materials for the compound semiconductor layer and changing a V/III ratio as a ratio of mol flow rates of the Group III organometallic source material and the Group V source material to modify a consumption amount of the growth species of the compound semiconductor layer at the slit, thereby to control the growth rate of the compound semiconductor layer at the mask opening.
It is preferable that the mask comprises a set of rectangular mask pieces having an opening at a central portion; the slits are arranged in parallel with the opening so as to pass through the mask pieces; and the growth rate of the compound semiconductor layer is controlled by the width of the slits.
It is preferable that the growth rate of the compound semiconductor layer is controlled by changing the number of the slits.
It is preferable that the growth rate of the compound semiconductor layer is controlled by changing location of the slit.
It is preferable that the growth rate of the compound semiconductor layer is controlled by changing the length of the slit in a longitudinal direction.
It is preferable that the growth rate of the compound semiconductor layer is controlled by changing the width of the mask in a longitudinal direction.
In accordance with the method for forming a film by selective area growth of MOCVD technique of the present invention, the mask has the slit formed therein to control the growth rate of the compound semiconductor layer at the opening, and the growth species for the compound semiconductor layer which have reevaporated or diffused on the mask are consumed at the slit. Because the growth species supplied to the opening decreases in comparison with a case of using a slitless mask, and the compound semiconductor layer is grown at the opening at a growth rate that is higher than that at a region quite away from the mask on the semiconductor substrate and is lower than that in the case of the slitless mask, the increase rate in growth rate at the mask opening can be restrained.
The growth species for a compound semiconductor layer are grown at the slit while forming a non-growth surface of a (111) B plane. The growth species self-stop growing when the growth species have had an isosceles triangle cross-section, and after that the growth species are not consumed at the slit. As a result, the compound semiconductor layer is grown at the opening at a growth rate similar to the case of using the slitless mask, and the growth rate at the mask opening can be restrained only during a specific growth period.
When the V/III ratio as a ratio of mol flow rates of a Group III organometallic source material and a Group V source material is higher than certain value, growth occurs on the (111) B plane as well, and the V/III ratio is lower than the certain value, growth dose not occur on the (111) B plane. From this standpoint, the V/III ratio can be changed to modify the consumption amount of the growth species for a compound semiconductor layer at the slit, thereby controlling the growth rate at the mask opening arbitrarily.
The slit can be arranged in parallel with he mask opening so as to pass through the mask, thereby controlling the growth rate at the mask opening throughout the entire region of the mask.
The width, the number and the location of the slit(s) can be changed to modify an effective mask width before and after growth has self-stopped at the slit. In this manner, the degree of restraint in growth rate at the mask opening can be controlled.
The length of the slit in a longitudinal direction can be changed to control the growth rate at a specific region of the mask opening in the longitudinal direction.
The width of the mask in the longitudinal direction can be changed to control the growth rate at a specific region of the mask opening in the longitudinal direction.
As explained, in accordance with the method for forming a film by selective area growth of MOCVD technique of the present invention, the mask can have the slit formed therein to decrease the supply amount of the growth species to the mask opening, thereby restraining the increase rate in growth rate at the opening. Because the same increase rate in growth rate as the case of using the conventional slitless mask can be obtained at the mask opening after having self-stopped growing at the slit, the increase rate in growth rate for every structural layer can be controlled during collectively selective area growth of a semiconductor optical waveguide structure and so on.
The width, the number and the location of the slit(s) can be changed to control the degree of restraint of increase rate in growth rate at the mask opening.
The length of the slit and the mask width in the longitudinal direction can be changed to modify the region where the increase rate in growth rate is controlled, thereby restraining the layer thickness of an arbitrary semiconductor layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1(a) is a top plan view of a mask used in a first embodiment according to the present invention;
FIG. 1(b) is a cross-sectional view of the mask;
FIG. 1(c) is a cross-sectional view showing a growing state wherein a lower cladding layer is growing after commencement of growth in the first embodiment;
FIG. 1(d) is a cross-sectional view showing a growing state wherein the lower cladding layer growth has been completed in the first embodiment;
FIG. 1(e) is a cross-sectional view showing a growing state wherein an MQW waveguide layer and an upper cladding layer growth have been completed in the first embodiment;
FIG. 1(f) is a graph showing a change in the increase in growth rate with regard to growth time at the mask opening in the first embodiment;
FIG. 2(a) is a cross-sectional view showing grown layers according to a second embodiment of the present invention;
FIG. 2(b) is a graph showing a change growth rate with regard to growth time at the mask opening according to the second embodiment;
FIG. 3(a) is a top plan view showing a mask used in a third embodiment;
FIG. 3(b) is a cross-sectional view showing grown layers in the third embodiment;
FIG. 3(c) is a graph showing a change growth rate with regard to growth time in the third embodiment;
FIG. 4(a) is top plan view showing a mask wherein slits are formed in inner portions of mask elements in accordance with the fourth embodiment;
FIG. 4(b) is a top plan view showing a mask wherein slits are formed in central portions of mask pieces;
FIG. 4(c) is a top plan view showing a mask wherein slits are formed in outer portions of mask pieces;
FIG. 4(d) is a graph showing a change in growth rate with regard to growth time at the mask opening in the fourth embodiment;
FIG. 5(a) is a top plan view showing a mask used in a fifth embodiment of the present invention, wherein mask elements have two slits having the same width, respectively;
FIG. 5(b) is a top plan view of a mask used in the fifth embodiment, wherein mask elements have two slits having different widths, respectively:
FIG. 5(c) is a cross-sectional view showing a growing state wherein growth is occurring at the slits after growth commencement in accordance with the fifth embodiment;
FIG. 5(d) is a cross-sectional view showing a growing state which is obtained when growth stops at narrower slits in accordance with fifth embodiment;
FIG. 5(e) is a cross-sectional view showing a growing state which is obtained when growth has stopped at the respective slits in accordance with the fifth embodiment;
FIG. 5(f) is a graph showing a change in growth rate with regard to growth time in the fifth embodiment;
FIG. 6(a) is a top plan view of a mask used in a sixth embodiment;
FIG. 6(b) is a graph showing a change in growth time with regard to an increase in growth rate along the section line a-a' and along the section line b-b' in FIG. 6(a);
FIG. 6(c) is a graph showing a change growth rate with regard to location along the section line x-y at the center of the mask opening in FIG. 6(a);
FIG. 7(a) is a top plan view of a mask used in a seventh embodiment;
FIG. 7(b) is a graph showing the grown layer thickness along the line x-y in FIG. 7(a);
FIG. 8(a) is a top plan view showing a conventional mask;
FIG. 8(b) is a cross-sectional view showing the conventional mask;
FIG. 8(c) is a cross-sectional view showing a growth layer when using the conventional mask; and
FIG. 8(d) is a graph showing a change in growth rate with regard to growth time at the mask opening of the conventional mask.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
EMBODIMENT 1
The basic embodiment of the film formation method in accordance with the present invention will be explained in reference to the accompanying drawings. Referring now to FIGS. 1(a) and 1(b), there are shown a top plan view of a mask used in this embodiment, and a cross-sectional view of the mask at its central portion. In those Figures, reference numeral 1 designates a mask element, reference numeral 2 designates a mask opening and reference numeral 3 designates a slit which passes between each of the rectangular mask elements 1 in a longitudinal direction. In this embodiment, the slits 3 are provided between the mask elements 1; The growth self-limiting function in (111) B plane growth at the slits, and a change in effective mask width in the growth time before and after the self-limiting are utilized to create a change in growth rate with regard to growth time.
Formation of the mask elements 1 will be explained. An SiO 2 film with a thickness of about 100 nm is formed on a pretreated (100) InP substrate, and a resist coating is applied to the film. A mask pattern shown in FIG. 1(a) is prepared using a photolithographic technique. After the InP substrate with the mask pattern formed thereon is pretreated with acid, the substrate is introduced into an MOCVD apparatus, for growing semiconductor layers.
FIG. 1(c) is a cross-sectional view showing how a lower cladding layer grows after growth commencement. Since the mask opening 2 and the slits 3 are regions sandwiched by the mask elements 1 growth rate is increased due to oversupply of growth species by reevaporation and vapor phase diffusion in a direction transverse to the mask of growth species on the mask elements. Although the growth rate at the mask opening 2 increases in proportion to an adjacent mask width, the increase is lower than that in the conventional mask at this stage because the mask is narrower than the conventional mask because of the presence of the slits 3. Growing portions of each growth layer in contact with mask edges have oblique surfaces at about 54 degrees to the InP substrate surface because non-growth surfaces in (111) B planes are exposed.
FIG. 1(d) is a cross-sectional view showing the growth which is obtained when the lower cladding layer growth has been completed. Although the mask opening 2 has growth continued at a low rate so that a trapezoidal sectional shape with non-growth surfaces in (111) B planes is exposed at the mask edges, the slits 3 have growth with an isosceles triangle cross-section having two sides at about 54 degrees to the InP substrate, which is obtained by further growth from the trapezoidal sectional shape. After this stage, the slits 3 do not have any additional growth, and growth stops because only the non-growth surfaces in (111) B planes are exposed.
FIG. 1(e) is a cross-sectional view showing completed growth of an MQW waveguide layer and an upper cladding layer. The slits 3 do not consume growth species because growth has stopped. This means that reevaporation of the growth species occurs at the slits 3 as on the mask elements 1. As a result, the effective mask width adjacent to the mask opening 2 is the same as the conventional slitless mask width at this stage.
FIG. 1(f) is a graph showing a change in growth rate with regard to growth time at the mask opening 2 in this embodiment. Between growth commencement and the time when at the slits 3 the grown sectional shape becomes an isosceles triangle, the growth rate is restrained to a lower level than the case of growth using the conventional mask. During this period, growth of the lower cladding layer is carried out and is completed. Subsequently, growth of the MQW waveguide layer and the upper cladding layer is carried out at the growth rate as the conventional mask.
In this embodiment, if growth of the isosceles triangle cross-section has been completed at the slits 3 during growth of the lower cladding layer, a portion of the lower cladding layer would be grown at the conventional growth rate, causing the layer thickness of the lower cladding layer to be thicker than a designed layer thickness. If growth of the isosceles triangle cross-section has been completed at the slits during e.g., growth of the subsequent MQW waveguide layer, after completion of growth of the lower cladding layer, only a portion of the MQW waveguide layer would be grown at the conventional growth rate to have a thicker layer thickness. As a result, only a portion of the thickness of a quantum well structure layer or a quantum barrier layer which forms the MQW would increase and adversely affect device performance because it is not possible to realize an even layer thickness and a periodic structure of a composition which are required for the MQW to obtain a desired performance. This means that it is important in the present invention to accurately control the time when growth of the isosceles triangle of cross-section has been completed at the slits 3. The growth completion time is determined by a relationship between the designed layer thickness of the lower cladding layer, and the growth rate at the mask opening 2, and the slit width the slit width is especially significant.
As explained, in accordance with this embodiment, the mask 1 can have the slit 3 to restrain the growth rate for only the lower cladding layer during collective growth. As a result, the grown layer thickness of the lower cladding layer is thinner than that grown using the conventional mask. Normally, the semiconductor waveguide structure is designed to have a layer thickness so that the MQW waveguide layer is as thin as 100 nm, and the upper and lower cladding layers are as thick as 500-1,000 nm, which means that 90-95% of the total layer thickness is occupied by upper and the lower cladding layers. When the layer thickness of the lower cladding layer is about one-half, the layer thickness of the entire semiconductor layers is reduced by about 30%, nonuniformities on the substrate surface decreases.
When the slits are opened to pass through the entire length of the mask, such an effect can be realized throughout the entire mask length.
EMBODIMENT 2
An effect which is obtained when the V/III ratio during growth is changed using the mask 1 described for the first embodiment will be explained with reference to a second embodiment. FIG. 2(a) is a cross-sectional view showing growth according to the second embodiment, and FIG. 2(b) is a graph showing a change in growth rate with regard to growth time at the mask opening 2. In the MOCVD growth, a Group III organometallic source material and a Group V source material are mixed and supplied in certain proportion, and the V/III ratio, i.e., the ratio of the flow rates ratio of the growth materials is a growth parameter. It is known that when growth is carried out at a raised V/III ratio, growth occurs on the (111) B planes as well. In accordance with the second embodiment, this principle is utilized to further restrain an increase in growth rate at the mask opening 2 in comparison to the first embodiment. The grown cross-section at the slits 3 becomes hexagonal as shown in FIG. 2(a) by carrying out growth under such a condition that the V/III ratio at the time of growing the upper and the lower cladding layer is higher than about 100 (the V/III ratio varies depending on device and growth parameters such as device structures and growth temperatures). This is because growth occurs on the oblique surfaces of the (111) B planes of the isosceles triangle of the first embodiment. The species reevaporated on the mask 1 is consumed there in a greater amount than in the first embodiment to decrease supply of the growth species to the mask opening 2. In this manner, the growth rate can be lowered as shown in FIG. 2(b) to further decrease the layer thickness of the upper and lower cladding layers. Conversely, the MQW waveguide layer can be grown at a low V/III ratio to prevent growth rate lowering at the mask opening 2.
Since growth on the (111) B planes can be changed by adjusting the V/III ratio to change the growth rate successively, the extent of the layer thickness decreasing effect can be changed at an arbitrary time during the same growth.
EMBODIMENT 3
An effect which is obtained when the mask elements 1 have plural slits 3 therein, respectively, will be explained with reference to this embodiment. FIG. 3(a) is a top plan view of the mask according to this embodiment. Each mask element has two slits 2 that pass through the mask in a longitudinal direction. The mask width and the mask opening width are the same as those in the first embodiment.
FIG. 3(b) is a cross-sectional view showing the growth which is obtained when the two slits 3 are formed in the respective mask elements 1.
Although the growing process at the slits 3 is the same as the first embodiment, the growth rate at the mask opening 2 is different depending on the number of the slits as shown in FIG. 3(c). Since an increase in the number of the slits 3 makes the mask width adjacent to the mask opening 2 narrower and decreases the excessive growth species supplied to the mask opening 2, the growth rate is lowered.
As explained, the growth rate at the mask opening 2 can be controlled depending on the number of the slits 3 in the mask 1.
EMBODIMENT 4
An effect which is obtained when location of the slits 3 in the mask 1 is changed will be explained with reference to this embodiment.
FIGS. 4(a), 4(b) and 4(c) are top plan views showing the mask 1 with the slits 3 in inner portions of the respective mask elements, the mask 1 with the slits 3 in central portions of the respective mask elements, and the mask 1 with the slits 3 formed in outer portions of the respective mask elements, respectively. A change in growth rate with regard to growth time in each case is shown in FIG. 4(d).
When the slits 3 are formed in the inner portions of the respective mask elements 1, the growth rate is lowers in comparison with the case of forming the slits 3 in the central portions of the respective mask elements because the mask width adjacent to the mask opening 2 is made narrower to decrease the excessive supply of growth species to the mask opening 2. Although this embodiment is based on the same principle as the third embodiment wherein the plural slits are formed, the extent of the decrease in growth rate is different. When the slits 3 are formed in the outer portions of the respective mask elements 1, the growth rate increases in comparison with the case of forming the slits 3 in the central portions of the respective mask elements 1 because the mask width adjacent to the mask opening 2 is made wider to increase the growth species supplied to the mask opening 2. In those cases, the increase in growth rate after self-limiting of growth at the slits 3 is the maximum increase rate which is determined by the entire mask width.
As explained, the increase rate in growth rate at the mask opening 2 can be controlled depending on location the slits 3 in the mask 1.
EMBODIMENT 5
An effect which is obtained when plural slits 3 having different slit widths are formed in the respective mask elements 1 will be explained with reference to this embodiment.
FIG. 5(a) is a top plan view showing a mask with two slits 3 having the same width in each mask element 1 like the third embodiment. On the other hand, FIG. 5(b) is a top plan view of a mask with two slits 3(a) and 3(b) having different widths in each mask element. FIGS. 5c(c), 5(d) and 5(e) are cross-sectional views showing the growth which is obtained when the mask 1 having each mask element including two slits different in width as shown in FIG. 5(b) is used. FIG. 5(f) is a graph showing a change in growth rate with regard to growth time which is obtained when the mask 1 having each mask element with the two slits different in width is used.
When the mask has in each mask element the two slits 3 having the same width, the growth rate can be lower for a certain period of time because of the time which is required for growth to self-stop at the slits 3 is the same for the two slits in each mask element. On the other hand, when the two slits are different in width in each mask element, the growth rate with regard to growth time changes in a two-stage manner as shown in FIG. 5(F) because the time when growth self-stops at the slits 3 is different For each slit.
When the mask 1 with two different slit widths is used, the slits 3a and 3b consume the growth species after growth commencement, and the mask width which contributes to the increase rate in growth rate at the mask opening 2 is the narrowest (FIG. 5c). Subsequently, growth self-stops at the slits 3a having a narrower width (FIG. 5d). Although growth is continuing at the slits 3b having the wider width at this stage to and consumes the growth species at the slits 3b, growth has self-stopped at the slits 3a having the narrower width. As a result, the mask width which contributes to the increase in growth rate at the mask opening 2 extends to the edges of the wider slits 3b, increasing the growth rate at the mask opening 2 to a higher level. When growth has self-stopped at the wider slits 3b (FIG. 5(e)), there is no consumption of the growth species at any slits because growth has self-stopped at all the slits. As a result, the mask width which contributes to a increase in growth rate at the mask opening 2 becomes the entire mask width, and the growth rate at the mask opening 2 increases further.
As explained, when plural slits which are different in width are formed, a change in growth rate with regard to growth time can be separated at a multi-stage manner.
EMBODIMENT 6
A two-dimensional restraint on an increase rate in growth rate which is obtained by changing the length of the slits 3 will be explained with reference to this embodiment. FIG. 6(a ) is a top plan view of a mask wherein the length of the slits 3 is limited to a portion of the mask elements in a longitudinal direction of the mask 1. The slits 3 do not pass through the mask 1 in the longitudinal direction. A change in growth rate with regard to growth time along the a-a' section line, and the b-b' section line of FIG. 6(a) in the case of using the mask 1 shown in FIG. 6(a) is shown in FIG. 6(b). At the a-a' section line, growth which is the same as the conventional growth is carried out, the increase in growth rate at the mask opening 2 is the maximum value which is determined by the mask width, and growth progresses at a certain increase rate irrespective of lapse of the growth time. On the other hand, along the b-b' section line, the increase in growth rate is restrained up to a certain growth time by the effect which was described in reference to the first embodiment.
In FIG. 6(c), such an effect is shown as a change in growth rate with regard to location at the x-y section in a central portion of the mask opening 2 in FIG. 6(a). In the time period from growth commencement to self-limiting of growth at the slits 3, only the increase in growth rate at a region in the vicinity of the slits 3 formed in the longitudinal direction of the mask is restrained and flattened. After that, in the time period from self-limiting of growth at the slit 3 to growth completion, growth is made with the conventional growth rate.
As explained, when the length of slits 3 is limited to a portion of the mask 1 in the longitudinal direction, the increase in growth rate at the mask opening 2 can be partially restrained only for a certain period of the growth time.
When the length of the slits 3 is separated into plural parts in a portion of the longitudinal direction of the mask 1, the increase in growth rate along the x-y section line in the central portion of the mask opening 2 can be separated into plural sections. This means that a plurality of functional elements can be collectively fabricated in the longitudinal direction of the mask 1.
EMBODIMENT 7
In FIG. 7(a), there is shown a seventh embodiment of the present invention. An effect which is obtained when the mask width changes in the longitudinal direction of the mask 1 will be explained with respect to this embodiment. FIG. 7(a) is a top plan view showing a mask 1 wherein two different mask widths, Wma and Wmb, are successively formed to have mask lengths La and Lb in the longitudinal direction of the mask, respectively. The mask opening width and the slit width are the same as those of the first embodiment.
When the mask 1 shown in FIG. 7(a) is used, the growth rate at the mask opening 2 at the a-a' section line, and that along the b-b' section are the same throughout the entire length of the mask up to the self-limiting of growth because the mask width adjacent to the mask opening 2 is common to both sections.
After self-limiting of growth at the slits 3, the a-a' section line has a greatly increased in growth rate because the mask width along the a-a' section line is Wma' effectively. On the other hand, along the b-b' section line there is a slightly increased growth rate because the mask width is Wmb' effectively. As a result, when the mask 1 shown in FIG. 7(a) is used, the growth which is obtained along the x-y section line in the central portion of the mask opening 2 is such that only the lower cladding layer has the same grown layer thickness at both mask lengths La and Lb, and the grown layer thickness of the MQW waveguide layer and the upper cladding layer has the region La in the mask length that is relatively thick and the region Lb in the mask length that is relatively thin.
As explained, when the mask width changes in the longitudinal direction of the mask, and the slits 3 are formed, the increase in growth rate can be changed in the longitudinal direction of the mask to restrain the layer thickness of an arbitrary semiconductor layer.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A method for forming a film by selective area growth by MDCVD technique includes forming a mask on a semiconductor substrate having a (100) plane, the mask having a mask opening to selectively growing a compound semiconductor layer, and a slit which is narrower than the mask opening in width and controls the growth rate of the compound semiconductor layer at the mask opening; and selectively growing the compound semiconductor layer at a growth rate which is on the mask in the mask opening and the slit.
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This is a continuation of U.S. patent application Ser. No. 08/317,670, filed Oct. 5, 1994 , now abandoned, which is a division of pending prior application Ser. No. 08/147,113 filed Nov. 3, 1993 now U.S. Pat. No. 5,403,172 issued Apr. 4, 1995 entitled SCROLL MACHINE SOUND ATTENUATION.
FIELD OF THE INVENTION
The present invention relates to scroll-type machinery. More particularly, the present invention relates to a novel method and apparatus for attenuating noise generated during the operation of the scroll-type machinery.
BACKGROUND AND SUMMARY OF THE INVENTION
Scroll machinery for fluid compression or expansion is typically comprised of two upstanding interfitting involute spirodal wraps or scrolls which are generated about respective axes. Each respective scroll is mounted upon an end plate and has a tip disposed in contact or near contact with the end plate of the other respective scroll. Each scroll further has flank surfaces which adjoin, in moving line contact or near contact, the flank surfaces of the other respective scroll to form a plurality of moving chambers. Depending upon the relative orbital motion of the scrolls, the chambers move from the radially exterior ends of the scrolls to the radially interior ends of the scrolls for fluid compression, or from the radially interior ends of the scrolls to the radially exterior ends of the scrolls for fluid expansion. The scrolls, to accomplish the formation of the chambers, are put in relative orbital motion by a drive mechanism. Either one of the scrolls may orbit or both may rotate eccentrically with respect to one another.
A typical scroll machine, according to the design which has a non-orbiting scroll, includes an orbiting scroll which meshes with the non-orbiting scroll, a thrust bearing to take the axial loads on the orbiting scroll and a motion controlling member for preventing relative rotation of the scroll members. The motion controlling member preferred for preventing relative rotation of the scroll members is usually an Oldham coupling.
In the marketplace, there is an increasing demand for much quieter machinery than was hitherto acceptable, and this is especially true for air conditioning and heat pump systems. In the case of refrigerant compressors used for air conditioning and heat pump applications, sound has become an increasingly important criteria for judging acceptability. There are a number of identified sources of sound in a scroll compressor, many of which are relatively easily cured. A recently discovered source of sound which does not lend itself to easy cure, however, concerns the mechanical impact noise or rattle which is caused by vibration of the motion controlling member in relation to various components of the compressor under certain operating conditions. These operating conditions include when the compressor is operating under lighter load conditions when there is insufficient loading of the compressor components including the motion controlling member to prevent force reversals which can cause the motion controlling member to impact noisily on the components of the compressor with which it interfaces and conditions when the motion controlling member wobbles within the compressor as a result of the interaction between the drive loads, gas forces, thrust bearings or other components of the compressor.
Accordingly, it would be desirable to insure that there is sufficient loading of the motion controlling member in all directions and at all operating conditions of the compressor to prevent the force reversals and the wobbling of the motion control member and thus eliminate the mechanical impact or rattle which is caused by the vibration of the motion controlling member.
It is therefore a primary objective of the present invention to provide means for biasing the motion controlling member in order to take up the normal build and operating clearances that are present in the scroll machinery which can contribute to the mechanical impact or rattle caused by the vibration of the motion controlling member.
Other advantages and objects of the present invention will become apparent to those skilled in the art from the subsequent detailed description, appended claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
FIG. 1 is a vertical sectional view through the center of a scroll type refrigeration compressor incorporating a biased motion controlling member in accordance with the present invention;
FIG. 2 is a sectional view of the refrigeration compressor of FIG. 1, the section being taken along line 2--2 thereof;
FIG. 3 is a fragmentary vertical section view similar to that of FIG. 1 but incorporating a different design of motion controlling member which is biased similar to that shown in FIG. 1;
FIG. 4 is a plan view of the motion controlling member incorporated in the refrigeration compressor shown in FIGS. 1 and 2, all in accordance with the present invention;
FIG. 4A is a graph depicting the combination of tangential gas forces and inertial gas forces acting on the motion controlling member in a first condition;
FIG. 4B is a graph depicting the combination of tangential gas forces and inertial gas forces acting on the motion controlling member in a second condition;
FIG. 5 is an elevational view of the motion controlling member shown in FIG. 4;
FIG. 6 is a schematic representation of the biasing of the motion controlling member using a cantilevered spring in accordance with another embodiment of the present invention;
FIG. 7 is a schematic representation of the biasing of the motion controlling member using a compressible fluid spring in accordance with another embodiment of the present invention;
FIG. 8 is a schematic representation of the biasing of the motion controlling member using a loop spring in accordance with another embodiment of the present invention;
FIG. 9 is a schematic representation of the biasing of the motion controlling member using a wishbone spring in accordance with another embodiment of the present invention;
FIG. 10 is a schematic representation of the biasing of the motion controlling member using a leaf spring in accordance with another embodiment of the present invention;
FIG. 11 is a schematic representation of the biasing of the motion control member using a dashpot in accordance with another embodiment of the present invention;
FIG. 12 is a sectional view similar to that shown in FIG. 2 but showing the biasing of the motion control member torsionally using a U-shaped spring in accordance with another embodiment of the present invention;
FIG. 13 is a schematic illustration of the orbiting scroll, the Oldham coupling and the main bearing housing accentuating the wobbling of the Oldham coupling;
FIG. 14 is a partial side elevational view showing the axial biasing of the motion control member using a leaf spring in accordance with another embodiment of the present invention;
FIG. 15 is a partial end view of the biasing of the motion control member shown in FIG. 14;
FIG. 16 is a partial end view showing the axial biasing of the motion control member using a coil spring in accordance with another embodiment of the present invention;
FIG. 17 is a plan view of the motion controlling member incorporated in the refrigeration compressor shown in FIG. 3; and
FIG. 18 is an elevational view of the motion controlling member shown in FIG. 17.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in which like reference numerals designate like or corresponding parts throughout the several views, there is shown in FIG. 1, a compressor 10 which comprises a generally cylindrical hermetic shell 12 having welded at the upper end thereof a cap 14 and at the lower end thereof a base 16 having a plurality of mounting feet (not shown) integrally formed therewith. Cap 14 is provided with a refrigerant discharge fitting 18 which may have the usual discharge valve therein (not shown). Other major elements affixed to the shell include a transversely extending partition 22 which is welded about its periphery at the same point that cap 14 is welded to shell 12, a main bearing housing 24 which is suitably secured to shell 12 and a lower bearing housing 26 having a plurality of radially outwardly extending legs each of which is suitably secured to shell 12. A motor stator 28 which is generally square in cross-section but with the corners rounded off is press fitted into shell 12. The flats between the rounded corners on the stator provide passageways between the stator and shell which facilitate the return flow of lubricant from the top of the shell to the bottom.
A drive shaft or crankshaft 30 having an eccentric crank pin 32 at the upper end thereof is rotatably journaled in a bearing 34 in main bearing housing 24 and a second bearing 36 in lower bearing housing 26. Crankshaft 30 has at the lower end a relatively large diameter concentric bore 38 which communicates with a radially outwardly inclined smaller diameter bore 40 extending upwardly therefrom to the top of crankshaft 30. Disposed within bore 38 is a stirrer 42. The lower portion of the interior shell 12 is filled with lubricating oil and bore 38 acts as a pump to pump lubricating fluid up the crankshaft 30 and into passageway 40 and ultimately to all of the various portions of the compressor which require lubrication.
Crankshaft 30 is rotatively driven by an electric motor including stator 28, windings 44 passing therethrough and a rotor 46 press fitted on crankshaft 30 and having upper and lower counterweights 48 and 50, respectively.
The upper surface of main bearing housing 24 is provided with a flat thrust bearing surface 52 on which is disposed an orbiting scroll 54 having the usual spiral vane or wrap 56 on the upper surface thereof. Projecting downwardly from the lower surface of orbiting scroll 54 is a cylindrical hub having a journal bearing 58 therein and in which is rotatively disposed a drive bushing 60 having an inner bore 62 in which crank pin 32 is drivingly disposed. Crank pin 32 has a flat on one surface which drivingly engages a flat surface (not shown) formed in a portion of inner bore 62 to provide a radially compliant driving arrangement, such as shown in assignee's U.S. Pat. No. 4,877,382, the disclosure of which is hereby incorporated herein by reference.
A non-orbiting scroll member 64 is also provided having a wrap 66 positioned in meshing engagement with wrap 56 of scroll 54. Non-orbiting scroll 64 has a centrally disposed discharge passage 68 which communicates with an upwardly open recess 70 which in turn is in fluid communication with a discharge muffler chamber 72 defined by cap 14 and partition 22. An annular recess 74 is also formed in non-orbiting scroll 64 within which is disposed a floating seal assembly 76. Recesses 70 and 74 and seal assembly 76 cooperate to define axial pressure biasing chambers which receive pressurized fluid being compressed by wraps 56 and 66 so as to exert an axial biasing force on non-orbiting scroll member 64 to thereby urge the tips of respective wraps 56 and 66 into sealing engagement with the opposed end plate surfaces. Seal assembly 76 is preferably of the type described in greater detail in U.S. Pat. No. 5,156,539, the disclosure of which is hereby incorporated herein by reference. Scroll member 64 is designed to be mounted to main bearing housing 24 in a suitable manner such as disclosed in the aforementioned U.S. Pat. No. 4,877,382 or U.S. Pat. No. 5,102,316, the disclosure of which is hereby incorporated herein by reference.
An Oldham coupling 80 is provided as a motion controlling member and is positioned between orbiting scroll 54 and bearing housing 24. Oldham coupling 80 is keyed to both orbiting scroll 54 and non-orbiting scroll 64 to prevent rotational movement of orbiting scroll member 54 with respect to non-orbiting scroll 64. Oldham coupling 80 is preferably similar to the type disclosed in assignee's copending application Ser. No. 591,443, entitled "Oldham Coupling For Scroll Compressor" filed Oct. 1, 1990, the disclosure of which is hereby incorporated herein by reference.
FIG. 3 illustrates the upper portion of a compressor 10' which includes a shell 12' and an Oldham coupling 80' which is provided as a motion controlling member and is positioned between an orbiting scroll 54' and a bearing housing 24'. Oldham coupling 80' is keyed to both orbiting scroll 54' and bearing housing 24' to prevent rotational movement of orbiting scroll member 54' with respect to a non-orbiting scroll 64'. Oldham coupling 80' is preferably similar to the type disclosed in assignee's U.S. Pat. No. 4,992,033, the disclosure of which is hereby incorporated herein by reference.
The present invention provides a unique arrangement for biasing Oldham coupling 80 or Oldham coupling 80' with respect to orbiting scroll 54 or 54', non-orbiting scroll 64 or 64', main bearing housing 24 or 24' or shell 12 or 12'. Oldham coupling 80, as best seen with reference to FIGS. 2, 4 and 5, includes an annular ring portion 82, the inner periphery of which is non-circular in shape being defined by two generally circular arc segments 84 and 86 each of a substantially constant radius R, the opposed ends of which are interconnected by substantially straight segments 88 and 90 of length L.
A pair of keys 92 and 94 are provided on annular ring 82 in diametrically aligned relationship and projecting axially upward from a surface 96 thereof. A second pair of keys 98 and 100 are also provided on annular ring 82 also projecting axially upward from surface 96 thereof. Keys 98 and 100 are aligned along a line extending parallel to a radius of arc 86 which radius is substantially perpendicular to the diameter along which keys 92 and 94 are aligned but shifted towards key 94. Additionally, keys 98 and 100 are positioned on outwardly projecting flange portions. Both the radial shifting and outward positioning of keys 98 and 100 cooperate to enable the size of Oldham coupling 80 to be kept to a minimum for a given size compressor and associated shell diameter while enabling the size of thrust surface 52 to be maximized for this same compressor as well as to avoid interference with the location and extent of wrap 56 of orbiting scroll member 54.
As shown in FIG. 2, the end plate of orbiting scroll member 54 is provided with a pair of outwardly projecting flange portions 102 and 104 each of which is provided with an outwardly opening slot 106. Slots 106 are sized to slidingly receive respective keys 98 and 100. Keys 98 and 100 will, of course, have an axial length or height so as to avoid projecting above the upper surface of the end plate of orbiting scroll member 54.
Referring once again to FIG. 1, non-orbiting scroll 64 is similarly provided with a pair of radially extending aligned slots 108 and 110 which are designed to receive respective keys 92 and 94. Of course, keys. 92 and 94 will be substantially longer than the keys 98 and 100 and of sufficient length to project above the end plate of scroll 54 and remain in engagement with slots 108 and 110 throughout the limited axial movement of non-orbiting scroll 64 noted above. It should be noted, however, that preferably a slight clearance will be provided between the end of respective keys 92 and 94 and the overlying surfaces of respective slots 108 and 110 when scroll member 64 is fully seated against scroll member 54 thereby avoiding any possibility of interference with the tip sealing between the respective scroll members.
As may now be appreciated, Oldham coupling 80 serves to directly interconnect and prevent any relative rotation between scroll members 54 and 64 through the cooperative action of the abutment surfaces provided by respective slots 106, 108 and 110 and associated keys 98, 100, 92, and 94. Similarly, the mounting arrangement of non-orbiting scroll 64 to bearing housing 24 will operate to effectively prevent relative rotation of non-orbiting scroll member 64 with respect to bearing housing 24 and hence also prevent relative rotation of orbiting scroll member 54 with respect to bearing housing 24.
The present invention utilizes a biasing member for applying load to Oldham coupling 80 in order to take up the manufacturing build and operating clearances. Oldham key loads are affected by many factors, but primarily, there are two major influences. These two influences include the tangential gas force and the resulting moment it creates and the inertia induced forces caused by the translational movement of the Oldham ring. The tangential gas force moment is dependent on operating conditions for the compressor but it can be considered quite uniform. It produces forces on orbiting scroll keys 98 and 100 as shown by F o in FIG. 4. The translational inertia is dependent on operating speed and is sinusoidal in nature. It affects only the orbiting scroll keys 98 and 100 and produces forces as shown by F I in FIG. 4. F I is a sinusoidal force which cycles between a positive and a negative value. Thus, the inertial forces F I both add and subtract from the tangential moment forces F o on orbiting scroll keys 98 and 100. The inertial forces F I do not directly affect the forces acting on non-orbiting keys 92 and 94.
FIG. 4A shows a summation of the two forces F o and F I when the value of F I is less than the value of F o . In this case, orbiting scroll keys 98 and 100 remained biased against one side of their respective slots 106. FIG. 4B shows a summation where the value of F I is greater than the value of F o . In this case, the loading on orbiting scroll keys 98 and 100 becomes negative for an instant during each rotation. This causes orbiting scroll keys 98 and 100 to vibrate within their respective slots 106 creating undesirable noise. The introduction of a single spring or a plurality of springs to directly oppose the inertial force component will ensure that keys 98 and 100 will never experience negative forces and thus not create the undesirable noise.
The embodiment shown in FIGS. 1 and 2 shows a pair of coil springs 120 and 122 disposed between main bearing housing 24 and Oldham coupling 80. A fifth and sixth key 124 and 126 are provided on Oldham coupling 80 projecting axially from a surface 128 thereof in a direction opposite from keys 92, 94, 98 and 100. Keys 124 and 126 respectively define pockets 130 and 132 for receiving coil springs 120 and 122 respectively. A corresponding pair of pockets 134 and 136 are located within main bearing housing 24. Pockets 130 and 134 operate to retain and guide coil spring 120 while pockets 132 and 136 operate to retain and guide coil spring 122. FIG. 3 shows a similar biasing for Oldham coupling 80'.
While FIGS. 1 and 2 illustrate Oldham coupling 80 that is biased by two coil springs 120 and 122 operating in opposite directions, it is within the scope of the present invention to only use coil spring 120 to bias Oldham coupling 80. The direction of biasing would then be determined by the spring type of coil spring 120. If coil spring 120 is selected to be a compression spring, the biasing of Oldham coupling 80 with respect to main bearing housing 24 will be radially outward. If coil spring 120 is selected to be an extension spring, the biasing of Oldham coupling 80 with respect to main bearing housing 24 will be radially inward. In the case of an extension spring, the opposite ends of coil spring 120 would have to be attached to Oldham coupling 80 and main bearing housing 24, respectively. Coil springs 120 and 122 are also shown in FIG. 3 biasing Oldham coupling 80' in a manner identical to that described above for Oldham coupling 80.
Oldham coupling 80', as best seen with reference to FIGS. 3, 17 and 18, includes an annular ring portion 82', the inner periphery of which is non-circular in shape being defined by two generally circular arc segments 84' and 86' each of a substantially constant radius R, the opposed ends of which are interconnected by substantially straight segments 88' and 90' of length L.
A pair of keys 92' and 94' are provided on annular ring 82' in diametrically aligned relationship and projecting axially downwardly from annular ring 82'. A second pair of keys 98' and 100' are provided on annular ring 82' in diametrically aligned relationship and projecting axially upwardly from annular ring 82'.
Referring now to FIG. 3, bearing housing 24' has a pair of radially extending aligned slots 108' and 110' which are designed to receive keys 92' and 94'. In a similar manner to that shown in FIG. 2, keys 98' and 100' are slidingly received in a pair of slots (not shown) in orbiting scroll 54' and bearing housing 24'.
The present invention utilizes coil springs 120 and 122 for applying load to Oldham Coupling 80' in order to take up the manufacturing, build and operating clearances similar to the embodiment disclosed in FIG. 1. The embodiment shown in FIG. 3 shows coil springs 120 and 122 disposed between main bearing housing 24' and Oldham coupling 80'. A pair of pockets 130' and 132' for receiving coil springs 120 and 122, respectively, are formed in downwardly extending keys 92' and 94'. A corresponding pair of pockets 134' and 136' are located within main bearing housing 24'. Pockets 130' and 134' operate to retain and guide coil spring 120 while pockets 132 and 136 operate to retain and guide coil spring 122.
For illustration purposes only, FIGS. 6 through 12 will illustrate various types of a biasing member acting on one side of Oldham coupling 80. It is to be understood that each biasing member illustrated in FIGS. 6 through 12 can act independently to bias Oldham coupling 80 or it can be combined with an additional biasing member acting in the opposite direction similar to the embodiment depicted in FIGS. 1 and 2. In addition, it is to be understood that the biasing members illustrated in FIGS. 6 through 12 may also be incorporated into the scroll compressor illustrated in FIG. 3 to bias Oldham coupling 80' similar to the way in which Oldham coupling 80 is biased.
FIG. 6 shows another embodiment of the biasing member of the present invention which is designated generally by the reference numeral 140. In the embodiment shown in FIG. 6, main bearing housing 24 is provided with an enlarged boss 142 which extends radially outward from main bearing housing 24 and provides a mounting area for biasing member 140. A support bolt 144 is fixedly secured to boss 142 by being threadingly received into a bore extending into boss 142 or support bolt 144 can be secured to boss 142 by other methods known well in the art. A cantilever spring 146 is attached to support bolt 144 by a nut 148 threadingly received on bolt 144 or by other means known well in the art. A spacer 150 positions cantilever spring 146 axially on support bolt 144. Cantilever spring 146 extends between support bolt 144 and the outside surface of Oldham coupling 80 to bias Oldham coupling 80 radially inward. Again it is possible to bias Oldham coupling 80 radially outward by attaching cantilever spring 146 to Oldham coupling 80 or by having cantilever spring 146 extend between support bolt 144 and the inside surface of Oldham coupling 80 if desired.
FIG. 7 shows another embodiment of the biasing member of the present invention which is designated generally by the reference numeral 160. Biasing member 160 is a piston and compressible fluid type of spring and comprises an intermediate pressure passageway 162 located through orbiting scroll member 54, an annular groove 164 disposed within thrust surface 52 of main bearing housing 24, an intermediate pressure biasing chamber 166 and a piston 168. Biasing chamber 166 is supplied with fluid at an intermediate pressure through groove 164 which is in turn supplied with fluid at intermediate pressure through passageway 162. Passageway 162 is open to an intermediate pressure area within compressor 10 at its upper end and is periodically open to groove 164 at its lower end during the operation of compressor 10. Piston 168 is slidingly received within chamber 166 such that the pressurized fluid within chamber 166 urges piston 168 radially outward against Oldham coupling 80 to provide the biasing of Oldham coupling 80.
FIG. 8 shows another embodiment of the biasing member of the present invention which is designated generally by the reference numeral 180. Biasing member 180 comprises a loop spring 182 having one end fixedly secured to main bearing housing 24 by a retainer 184. Retainer 184 may be threadingly received into a bore within main bearing housing 24 or retainer 184 may be secured to main bearing housing 24 by other means known well in the art. The opposite end of loop spring 182 contacts the inside surface of Oldham coupling 80 and exerts a biasing load radially outward against Oldham coupling 80. While the present embodiment is being shown as biasing Oldham coupling 80 radially outward, it will be appreciated that loop spring 182 could be configured to contact the outside surface of Oldham coupling 80 and thus bias Oldham coupling 80 radially inward if desired.
FIG. 9 shows another embodiment of the biasing member of the present invention which is designated generally by the reference numeral 200. Biasing member 200 comprises a wishbone spring 202 having a first leg 204 fixedly secured to shell 12 by welding or by other means known well in the art and a second leg 206 which contacts the internal surface of Oldham coupling 80 to bias Oldham coupling 80 radially outward. While being shown as biasing Oldham coupling 80 radially outward, it will be appreciated that wishbone spring 202 could be configured to contact the outside surface of Oldham coupling 80 and thus bias Oldham coupling 80 radially inward if desired. Also, while wishbone spring 202 is being shown in a generally vertical position, parallel to the axis of crankshaft 30, it is to be understood that wishbone spring 202 can be located at any angular position relative to the axis of crankshaft 30 in order to position wishbone spring 202 in the available space within shell 12.
FIG. 10 shows another embodiment of the biasing member of the present invention which is designated generally by the reference numeral 220. Biasing member 220 comprises a leaf spring 222 having a first leg 224, a second leg 226 and a central actuator portion 228. First and second legs 224 and 226 fit within corresponding apertures 230 and 232 located within a mounting bracket 234. Mounting bracket 234 is fixedly secured to shell 12 by welding or by other means known well in the art. The mounting of leaf spring 222 onto mounting bracket 234 positions central actuator portion 228 against the exterior surface of Oldham coupling 80 to bias Oldham coupling 80 radially inward. While mounting bracket 234 and leaf spring 232 are being shown in a generally vertical position parallel to the axis of crankshaft 30, it is to be understood that mounting bracket 234 and leaf spring 222 can be located at any angular position relating to the axis of crankshaft 30 in order to position mounting bracket 234 and leaf spring 222 in the available space within shell 12.
The various embodiments illustrated in FIGS. 1 through 10 illustrate the introduction of a biasing member to directly oppose the inertial force component acting on Oldham coupling 80 or 80'. The embodiment shown in FIG. 11 illustrates the introduction of a dashpot which opposes the translational motion of Oldham coupling 80 and thus acts as a biasing member.
FIG. 11 schematically shows another embodiment of the biasing member of the present invention which is designated generally by the reference numeral 240. Biasing member 240 comprises a dashpot 242 having a piston 244 integral with Oldham coupling 80 which is received in a cylinder 246 integral with lower bearing housing 24. Piston 244 is slidingly received within cylinder 246 and is sized such that axial motion of piston 244 within cylinder 246 causes a pumping action of suction gas within the compressor through a vent hole 248. If necessary, a seal (not shown) can be provided between cylinder 246 and piston 244 to insure the pumping of suction gas through vent hole 248. Vent hole 248 is sized to control gas flow into and out of cylinder 246 to allow for the negating of the inertial forces over a wide range of operating speeds of the compressor. In a similar manner, dashpot 242 may be incorporated into the compressor shown in FIG. 3 to bias Oldham coupling 80' similar to the way in which Oldham coupling 80 is biased.
The various embodiments shown in FIGS. 1 through 11 illustrate the introduction of a biasing or damping member to directly oppose the inertial force component acting on Oldham coupling 80 or 80'. The embodiment shown in FIG. 12 illustrates the introduction of a biasing member which compliments or adds to the moment acting on Oldham coupling 80 by the tangential gas forces. By increasing the moment acting on Oldham coupling 80, the situation depicted in FIG. 4B can be avoided and the loading on Oldham coupling 80 will always be similar to that depicted in FIG. 4A.
FIG. 12 shows another embodiment of the biasing member of the present invention which is designated generally by the reference numeral 260. Biasing member 260 comprises a U-shaped torsional spring 262 which is fixedly secured to shell 12 at 264 and to Oldham coupling 80 at 266. U-shaped spring 262 may be a braided cable or any other type of U-shaped spring. Once assembled between shell 12 and Oldham coupling 80, spring 262 is preloaded in a torsional direction by the assembling of Oldham coupling 80 into compressor 10. U-shaped torsional spring 262 thus allows Oldham coupling 80 to move freely in its translational movement while providing load in a torsional direction due to the U-looping of spring 262.
Orbiting scroll 54, in addition to its normal orbiting motion, wobbles as a result of the interaction between the drive loads, gas forces and thrust bearings. This wobbling action of orbiting scroll 54 in conjunction with Oldham key friction with their respective slots tends to impact some wobbling to Oldham coupling 80. In addition, inertial forces also work to move Oldham coupling 80 vertically. As shown in FIGS. 4 and 5, Oldham coupling 80 is designed such that the forces acting on the Oldham keys is not in the same horizontal plane as the center of mass of Oldham coupling 80. Because of this, a couple is created by the inertia and driving forces tending to cause rotation of Oldham coupling 80. In an effort to reduce or eliminate the wobbling of Oldham coupling 80, a biasing member can be incorporated to bias Oldham coupling 80 in an axial direction.
The biasing members previously described in FIGS. 1 through 12 bias the Oldham coupling in a specified direction, either radially or torsionally with respect to the compressor, in order to eliminate the noise or rattle caused by the keys of the Oldham coupling slapping against their respective slots whether these slots be located in the orbiting scroll, the non-orbiting scroll or the lower bearing housing. The embodiments shown in FIGS. 13 through 16 illustrate biasing of the Oldham coupling where the specified direction is axially with respect to the compressor.
FIG. 13 schematically represents the assembly of Oldham coupling 80, orbiting scroll 54 and lower bearing housing 24. Oldham coupling 80 is located between two horizontal and generally parallel surfaces. These two surfaces are the lower surface 302 of orbiting scroll 54 and fiat thrust bearing surface 52 of main bearing housing 24. Vertical motion of Oldham coupling 80 is limited by contact of a plurality of Oldham pads 304 disposed on Oldham coupling 80 which contacts these two surfaces 302 and 52. Oldham coupling 80 is guided in its translational movement by non-orbiting scroll keys 92 and 94 while being driven by orbiting scroll keys 98 and 100. As Oldham coupling 80 is driven, inertial and frictional forces tend to cause the plurality of Oldham pads 304 to intermittently contact surfaces 302 and 52. Each time a pad 304 makes contact with either surface 302 or surface 52, the impact contributes to the overall sound level of compressor 10. The embodiments shown in FIGS. 14 through 16 bias Oldham coupling 80 against one of the surfaces 302 or 52 to control the magnitude of the impact between pads 304 and either surface 302 or surface 52.
FIGS. 14 and 15 illustrate schematically the use of a leaf spring 310 to bias Oldham coupling 80 in an axial direction. Leaf spring 310 is disposed between Oldham coupling 80 and surface 302 on orbiting scroll 54 to bias Oldham coupling 80 towards surface 52 on main bearing housing 24. Depending on the quantity and rate of leaf spring 310, the wobbling of Oldham coupling may be reduced or eliminated as Oldham coupling 80 is biased against surface 52 of main bearing housing 24. Leaf spring 310 may be fixedly secured to Oldham coupling 80 or may be located within a recess (not shown) in Oldham coupling 80 in order to resist the relative motion between orbiting scroll 54 and Oldham coupling 80.
FIG. 16 illustrates schematically the use of a coil spring 320 and a button 322 located within a bore 324 extending axially into non-orbiting scroll keys 92 of Oldham coupling 80. While FIG. 16 schematically illustrates coil spring 320 and button 322 within scroll key 92, it is to be understood that a similar coil spring 320 and button 322 may be incorporated into scroll key 94 to maintain symmetrical loading of Oldham coupling 80 if desired. Coil spring 320 urges button 322 into contact with the upper surface 326 of slot 108 located in non-orbiting scroll 64. In this manner, Oldham coupling 80 is biased towards surface 52 on main bearing housing 24. In order to symmetrically load Oldham coupling 80, both non-orbiting scroll keys 92 and 94 would include bore 324, coil spring 320 and button 322. Depending on the rate of coil springs 320, the wobbling of Oldham coupling 80 may be reduced or eliminated as Oldham coupling 80 is biased against surface 52 of main bearing housing 24. Button 322 allows for the translational movement of Oldham coupling 80 within slots 108.
While the above description of the preferred embodiments have been shown for exemplary purposes associated with a specific design of Oldham coupling, it is to be appreciated that one skilled in the an can modify the biasing means of the present invention to be used with other designs of Oldham couplings without departing from the scope, spirit and fair meaning of the present invention, as defined in the subjoined claims.
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A scroll-type machine has a motion controlling member for preventing relative rotation between a first and a second scroll member while allowing relative orbiting motion therebetween. The scroll-type machine includes a novel arrangement of a spring or other flexible member for biasing the motion controlling member in a specific direction. The biasing of the motion controlling member operates to reduce the mechanical impact noise or rattle which is caused by the vibration of the machine's operating components.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/335,463, having a filing date of Jan. 6, 2010, titled “Foldable Solar Panel Support System,” the complete disclosure of which is hereby incorporated by reference.
FIELD
[0002] The present invention relates generally to the field of transportable solar panels and more specifically it relates to a foldable solar panel and support system.
BACKGROUND
[0003] This section is intended to provide a background or context to the invention recited in the claims. The description herein may include concepts that could be pursued, but are not necessarily ones that have been previously conceived or pursued. Therefore, unless otherwise indicated herein, what is described in this section is not prior art to the description and claims in this application and is not admitted to be prior art by inclusion in this section.
[0004] Certain types of foldable solar panels are generally known, and are typically made of several fairly rigid solar cells sewn or attached to fabric allowing them to be folded (e.g. much like a map). These devices are intended to be portable for things such as camping or other “away from the grid” activities. As such a user is never certain what means will be available at the desired destination to “set up” the device upon.
[0005] One purpose of the invention is to provide a system for supporting a transportable (e.g. foldable or flexible, etc.) solar panel and to allow a user to prop or otherwise support the foldable solar panel quickly and conveniently, without the use of large or cumbersome stands or other parts, and to allow folding for lightweight and compact portability and also to more efficiently receive sunlight.
[0006] Accordingly, it would be desirable to provide a transportable photovoltaic solar panel and support system that overcomes the disadvantages of the conventional systems.
SUMMARY
[0007] One embodiment of the invention relates to a transportable solar panel and support system having a sheet of flexible material with a first side and a second side. A plurality of photovoltaic solar panels are coupled to the first side of the sheet of flexible material, with the solar panels spaced apart from one another by gaps to permit the sheet of flexible material to be configured in an unfolded condition so that the solar panels can receive sunlight, and a folded condition where the solar panels are stacked adjacent one another for transport. A storage compartment is disposed on the sheet of flexible material, and a plurality of receptacles are disposed on the second side of the sheet of flexible material, with at least a portion of the receptacles axially aligned with one another to span one or more of the gaps between the solar panels. A plurality of support members are disposed within the storage compartment when the sheet of flexible material is in the folded condition, and are disposed within the receptacles and span one or more of the gaps between the solar panels when the sheet of flexible material is in the unfolded condition.
[0008] Another embodiment of the invention relates to a transportable solar panel and support system having a flexible base, and a plurality of photovoltaic solar panels coupled to the flexible base. The solar panels are spaced apart from one another by gaps to permit the flexible base to be configured in an unfolded condition so that the solar panels can receive sunlight, and a folded condition where the solar panels are arranged at least partially adjacent to one another. A storage compartment and a plurality of receptacles are disposed on the flexible base, with at least a portion of the receptacles axially aligned with one another to span one or more of the gaps between the solar panels. A plurality of support rods are provided that are movable between a stowed position within the storage compartment when the flexible base is in the folded condition, and a deployed position within the receptacles and spanning one or more of the gaps between the solar panels when the flexible base is in the unfolded condition.
[0009] A further embodiment of the invention relates to a method of providing a transportable solar panel and support system, and includes the steps of providing a flexible base, and coupling a plurality of photovoltaic solar panels to the flexible base, and spacing the solar panels apart from one another by gaps to permit the flexible base to be unfolded so that the solar panels can receive sunlight, and folded where the solar panels are arranged at least partially adjacent to one another, and coupling a storage compartment to the flexible base, and providing a plurality of receptacles on the flexible base, at least a portion of the receptacles axially aligned with one another to span one or more of the gaps between the solar panels, and providing a plurality of support rods, the support rods being movable between a stowed position within the storage compartment when the flexible base is folded, and a deployed position within the receptacles and spanning one or more of the gaps between the solar panels when the flexible base is unfolded.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:
[0011] FIG. 1 is a schematic representation of a rear view of the transportable solar panel and support system in operation, and showing its general features including the rods being fastened to fabric or material on the opposite side of solar panels, according to an exemplary embodiment.
[0012] FIG. 2 is a schematic representation of a front view of the transportable solar panel and support system showing the rigid solar cells, a compartment to store a plurality of support rods, and a closure device for securing the compartment, according to an exemplary embodiment.
[0013] FIG. 3 is a schematic representation of a rear view of a transportable solar panel and support system, showing the use of collapsible support rods, according to an exemplary embodiment.
[0014] FIG. 4 is a schematic representation of a rear view of a transportable solar panel and support system, showing the use of support rods in a diagonal arrangement, according to an exemplary embodiment.
DETAILED DESCRIPTION
[0015] Referring to the FIGURES, a transportable solar panel and support system is shown according to an exemplary embodiment to include, as main elements, the following items: a support rod or rods or other similar elongated and rigid members, a flexible or foldable base (e.g. fabric, material, etc.), solar panels coupled to the flexible base, a compartment (e.g. pouch or storage device) with a closure to hold such support rods while not in use (i.e. when the flexible base is folded to a transport position), and receptacles on the flexible base that receive the support rods for rigidifying the flexible base and supporting the solar panels in a deployed position.
[0016] There has thus been broadly outlined some of the features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter.
[0017] In this respect, before explaining any embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction or to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.
[0018] According to one embodiment, the transportable solar panel and support system is intended to provide a flexible or foldable solar panel support system to provide lightweight and compact support to an otherwise ‘floppy’ foldable array of individual solar panels attached to the base, which when in the deployed position is typically leaned against something such as a rock or tree or the like and still will likely collapse on itself. The ability to rigidify and support the flexible base when in the deployed position is intended to allow the solar panels to more easily and effectively be pointed “normal” to the sun where they achieve the highest efficiencies.
[0019] According to another embodiment, the transportable solar panel and support system is intended to provide a foldable solar panel and support system that utilizes collapsible support rods interconnected by an elastic cord, in a manner similar to poles such as are common in tent construction, and which could easily be stored with the storage compartment and then be assembled/expanded to span the desired height of the flexible base to providing a contiguous rigidifying strategy, rather than a segmented rigidifying strategy.
[0020] According to another embodiment, the transportable solar panel and support system is intended to provide a foldable solar panel and support system in which such support rods could be positioned various ways such as vertically or diagonally (e.g. such as making and “X” across the back of the panels) or other suitable support pattern.
[0021] According to another embodiment, the transportable solar panel and support system is intended to provide a foldable solar panel support system where the receptacles are provided in the form of thin pockets, rings, or perhaps just tucked into pockets on either end of the flexible base, such that the support rods could be slid therethrough.
[0022] Referring further to the FIGURES, the components of the invention as shown according to the illustrated embodiment include: a flexible base 1 (e.g. foldable or flexible member such as a sheet of material), a plurality of support members 2 (e.g. support rod, post or other similar securing unit made of a substantially rigid material), receptacles 3 (e.g. fabric loops, pockets or other material or devices designed and positioned to hold the support rod in place on the flexible base), a storage compartment 4 (e.g. pouch, etc.) to hold or store the storage rods when not deployed (i.e. with the flexible base in the folded condition for transport), a closure device 5 (e.g. hook and loop fastener such as Velcro® of the like, snaps, zipper, or other fastening device to close the storage compartment for holding the support rods, a vertical folding axis 6 , a horizontal folding axis 7 , collapsible support rods 8 ; diagonally extending support rods 9 , diagonally disposed receptacles 10 , a plurality of photovoltaic solar cells or panels 11 coupled to the flexible base and spaced apart to form a clearance or flexible gap section 12 .
[0023] One operational concern associated with such transportable solar panel systems is how to get them pointed “normal” to the sun where they achieve highest efficiencies. For much of the day this is not straight up, but rather at some angle above the horizon. When a foldable, and therefore non-rigid panel is set up, it invariable has difficulty simply being leaned against something such as a rock, or tree, as it will collapse on itself, not having sufficient rigidity throughout its height. The invention according to the illustrated embodiments and as described herein addresses this concern.
[0024] As shown in the FIGURES, a plurality of support rods 2 are stored in the compartment 4 of the flexible base 1 as it is folded up for transport. The compartment 4 is fastened shut by closure device 5 . In order to deploy the solar panel system, the flexible base 1 is unfolded and the support rods 2 are removed from compartment 4 and inserted at least partially into receptacles 3 (e.g. slid into or through narrow pockets, or loops attached to the back of the flexible base that span one or more of the flexible gap sections 12 between the solar cells. By thus “bridging” gap sections 12 , the flexible base 1 is rigidified sufficiently to be leaned upon or against something without collapsing on itself. In the preferred embodiment, the support rods 2 are approximately half the width of the unfolded flexible base, or in other words, the length of the folded base. To sufficiently rigidify the flexible base, it is generally not necessary to add stiffness along the entire height or length, but rather just enough to span the flexible gap sections 12 . The inherent rigidity of the solar cells 11 tend to provide the remaining needed stiffness.
[0025] There are other ways this stiffness could be achieved which may have advantages due to various factors such as loose stitching, fabric stretch and other factors that may still make it desirable to have even more stiffness than described above. Referring to FIG. 3 , collapsible support rods 8 may be provided having segments that are interconnected by an elastic cord, or that fit within each other end-to-end (such as are common in tent pole construction or the like) could also easily be stored with the storage compartment 4 and then be assembled or expanded to span the entire height of the flexible base 1 , thus providing a contiguous rigidifying strategy, rather than a segmented rigidifying strategy.
[0026] Referring to FIGS. 3 and 4 , according to other embodiments the support rods 2 or 8 or 9 may be positioned various ways such as horizontally, vertically or diagonally (such as making and “X” pattern across the flexible base. Also, the rods may be provided in sizes that are longer or shorter than half the width of the unfolded flexible base. Further, the receptacles may be provided as thin pockets, rings, or pockets disposed about the flexible base (e.g. sewn onto or otherwise formed in a sheet of a flexible material, etc.) and configured to receive the support rods (e.g. in a sliding relationship, etc.). According to an alternative embodiment, the solar panels may be provided in a single column or row, such that they can be supported in a deployed position by a single support rod.
[0027] According to any preferred embodiment, a transportable solar panel and support system is provided that is quickly and easily assembled by unfolding a flexible base having solar panels attached thereto, and rigidifying the flexible base using self-contained support rods that are configurable in any one of a variety of patterns or configurations, so that the deployed and rigidified system may be oriented toward the sun to obtain higher efficiencies without collapsing. The system is intended to be used by hikers, campers, outdoor enthusiasts and others who wish to harness the full power of their solar panels without the worry of what object they may lean or rest it upon when the reach a desired destination. The support rods may attach to the back of the flexible base and span one or more of the flexible gap sections between the solar panels. The support rods then act as a temporary support for the otherwise flexible (and perhaps flimsy) transportable solar panel.
[0028] As utilized herein, the terms “approximately,” “about,” “substantially,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.
[0029] It should be noted that the term “exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).
[0030] The terms “coupled,” “connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.
[0031] It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.
[0032] It is also important to note that the construction and arrangement of the systems and methods for installing solar panels as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter disclosed herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present inventions.
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A transportable solar panel and support system has a flexible base, and a plurality of photovoltaic solar panels coupled to the flexible base. The solar panels are spaced apart from one another by gaps to permit the flexible base to be configured in an unfolded condition so that the solar panels can receive sunlight, and a folded condition where the solar panels are arranged at least partially adjacent to one another. A storage compartment and receptacles are disposed on the flexible base, with at least a portion of the receptacles axially aligned with one another to span one or more of the gaps between the solar panels. Support rods are provided that are movable between a stowed position within the storage compartment when the flexible base is in the folded condition, and a deployed position within the receptacles and spanning one or more of the gaps between the solar panels when the flexible base is in the unfolded condition.
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BACKGROUND OF THE INVENTION
This invention relates to floor and roof constructions, and more particularly, to steel joists having supports for spanner bars which are used to support form work for pouring concrete slabs in place on steel joists.
In some methods of constructing floors and roofs, steels joists which are positioned to span structural supports hold forms, such as plywood sheets, and concrete is poured on the panels to form a slab. It is desirable to be able to reuse the panels and the supporting structure for the panels after the concrete has hardened and the forms are removed. In order to reuse the panels, the forms must be supported in such a way that they can be removed with little or no damage to them, and the prior art teaches a variety of techniques and apparatus for supporting forms in such a way that they can be removed and reused. However, some of the methods and apparatus are not applicable to open web joist systems; some of which may be used with open web joist systems are difficult to use in practice; and some of the methods and apparatus may raise safety questions.
The elements which support the panels must be kept from being encased in the concrete which is poured in order to be able to reuse them. In one type of system, metal bars, referred to herein as spanner bars, extend between adjacent joists and provide support for the concrete forms. The prior art methods of supporting spanner bars at the joists, especially at open web joists, can present problems in assembly, disassembly, adjustability, adaptability to a variation of joist structures, and safety.
The spanner bars typically are supported at or near the upper chord and have support means which are adapted to cooperate with or are an integral part of the upper chord. Some of these support means require special configurations for the top chord and the support means are typically encased in concrete and hence not reusable.
It is desirable that the support for the spanner bars can be assembled and disassembled by relatively unskilled labor using only simple tools. In handling heavy members of structural steel, workers usually wear gloves, and it is desirable that a minimum of care and little manual dexterity be needed to assemble and disassemble the elements of the support apparatus.
SUMMARY OF THE INVENTION
It is accordingly one object of this invention to provide apparatus for supporting a spanner bar at a joist which permits easy assembly and disassembly of the apparatus and the joist.
It is another object to provide apparatus for supporting a spanner bar at a joist which is readily adjustable in a longitudinal direction along the joist.
It is another object of this invention to provide apparatus for supporting a spanner bar at a joist which can accommodate a wide variation of joist sizes.
It is still another object of this invention to provide apparatus for supporting a spanner bar at or near the upper chord of a joist, yet which does not require securing the apparatus to the upper joist.
Other objects of this invention will be obvious from the drawings and the detailed description of the invention which follows.
In accordance with this invention there has been provided a combination of a bar joist which includes an upper chord, a lower chord comprising at least one metal angle bar, and an open web secured to the upper and lower chords and triangulating the space therebetween, and adjustable support means secured to the angle bar of the lower chord for supporting a spanner bar. The adjustable support means comprises a base member, means for securing the base member to an angle bar of said lower chord, a first vertically extending elongated member affixed to the base member, a second vertically extending elongated member cooperating with said first member and axially movable therewith, and means for axially moving said second member with respect to said first member and for restricting downward movement of said second member.
This invention provides apparatus for supporting the spanner bars from the lower chord of a joist in which the apparatus is readily movable longitudinally along the lower chord and can readily be adjusted to accommodate joists having a variety of sizes. It is not necessary for the joist to include any special structural features, and an open web joist having at least one angle bar at the lower chord oriented so that one leg of the angle bar is horizontal is all that is required. Furthermore, the apparatus is reusable since by its attachment to the lower chord instead of the upper chord, no part of it becomes incorporated in the concrete slab.
This apparatus is especially useful in combination with open web joists in which the upper chord comprises a pair of spaced-apart angle bars which are adapted to retain concrete between them when pouring the concrete which forms the slab. Ridge-like projections which are thus formed on the lower side of the slab and depend into the channel between the angle bars of the upper chord bear against the upper portion of the bars which form the open web and thus restrict relative horizontal movement between the concrete of the slab and the joists. The present apparatus is particularly useful in conjunction with elements for forming the resulting key-like structure because of its independence from support by the upper chord and the resulting lack of auxiliary structure at the upper chord which tends to interfere with elements which are necessary to form key-lock structures. Co-pending application Ser. No. 829,891, filed Feb. 18, 1986, describes these key-like structures in more detail, and matter in that application which describes such structure is hereby incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an open web joist, an embodiment of the adjustable support means of this invention which is attached to the lower chord thereof, and a spanner bar.
FIG. 2 is a sectional view of the open web joist, adjustable support means and spanner bar of FIG. 1.
FIG. 3 is a view in section of the adjustable support means shown in FIGS. 1 and 2.
FIG. 4 is a view of the adjustable support means of FIG. 3 from the right hand side thereof.
FIG. 5 is a side view of an alternate embodiment of the adjustable support means.
FIG. 6 is a sectional view of another embodiment of the adjustable support means of this invention.
FIG. 7 is a sectional view of a top joist with means for retaining concrete in the channel between two angle bars.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, FIG. 1 shows adjustable support means 20 (see FIG. 4) mounted on an angle bar 8 of the lower chord of open web steel joist 2 and supporting a spanner bar 14. The open web steel joist 2 comprises an upper chord formed from angle bars 4 and 6 and a lower chord formed from angle bars 8 and 10 which are interconnected and spaced apart by web 12. The support 20 comprises a base member shown in the Figures as a short piece of angle bar 22 having channel member 24 affixed to the vertical leg thereof as by welding. The bottom portion of the channel member 24 is spaced upwardly from the horizontal leg of angle bar 22 sufficiently far to permit a horizontal leg of an angle bar of the lower chord to be inserted in the gap between the two. The horizontal leg of the bar 22 is provided with a threaded hole to accommodate thumb screw 30 which is adapted to force the horizontal leg of an angle bar 8 against the lower edge 25 of channel member 24. Upper channel member 28 fits snugly within channel member 24 and is vertically movable towards and away from base member 22. The lower edge 29 of channel member 28 is supported by the upper edge 33 of wedge 32 which passes through slots 26, 27 in channel member 24. The upper surface 33 of wedge 32, in bearing against the lower edge 29 of member 28, forces the upper surface 34 against the lower edge of spanner bar 14, thus securing the spanner bar against the upper chord.
This invention contemplates a spanner bar support structure in which member 28 is secured to the spanner bar 14, as by welding, as well as structure in which member 28 is not affixed to the spanner bar 14.
The adjustable support means 20 is readily adaptable for use with a variety of sizes of joists, either by changing channel member 28 from one length to another, or by using wedges of different sizes.
The size and shape of wedge 32 is selected to permit easy placement of channel 28 under spanner bar 14 when the wedge is in the retracted position and to have the upper edge 34 bear against the spanner bar when the wedge is driven in place. Slots 26 and 27 through which wedge 32 is moved may be relatively short, i.e., they may have a length about that of wide edge 36 of wedge 32, or they may extend a major portion of the length of channel 24. The long slots permit great flexibility in use of the support means 20 since the length of the slot determines the maximum size of the wedge which may be used. The potential for use of wedges having a variety of lengths of sides 36 makes the support 20 readily adaptable for use with joists having different bottom chord to top chord spacings.
The wedge angle must be selected so that frictional forces will retain the wedge in place against downward forces from the spanner bar which tend to move the wedge outwardly. A relatively small angle, such as 10°14 20° is preferred since these small angles resist failure of the support by forcing the wedge out of the slots, and further, provide a high mechanical advantage in forcing the spanner bar upwardly when the supporting apparatus is put in place. Typically, the wedge is driven tightly in place by hammering. An example of a useful wedge is one having the upper edge at an angle of about 15° with the lower edge. For a wedge about 4 inches long, this permits a vertical movement of the axially movable channel from about 1/2 to about 3/4 of an inch.
FIGS. 1-4 show a spanner bar support wherein the axially movable channel 28 is insertable within the fixed channel 24. This invention also contemplates apparatus wherein the lower fixed channel has a smaller cross-sectional area than the upper channel and is insertable into the upper axially movable channel. While both channel members are shown in the drawings as having a square cross-section, channels having other shapes with rectangular cross-sections, or even channels having circular cross-sections are contemplated.
The drawings show the use of thumb screw 30 to secure the base member 22 to an angle bar of the lower chord. Other types of screws or threaded bolts may also be used and other clamping means are contemplated and may readily be devised by workers in the art. However, it is preferred that the securing means be operable without the use of hand tools or the need for more than a slight degree of manual dexterity to secure the base member 22 onto the angle bar of the lower chord of the open web joist.
Spanner bar supports other than those which are activated by a wedge are contemplated,, and FIG. 5 shows an alternate embodiment of the spanner bar support in which threaded bar 28a is vertically movable within threaded pipe 26a by rotating bar 28a. Means, not shown, such as a bar extending horizontally through a hole in the upper part of bar 28a, may be used to help rotate bar 28a.
In FIG. 6, which shows another embodiment of this invention, an angle bar 14a as a spanner bar is interconnected with base members 22b by turnbuckles 50. The spacing between base members 22b and spanner bar 14a is adjusted by rotating sleeves 40 which changes the spacing between upper bolts 28b and lower bolts 24b of the turnbuckle.
As shown in FIG. 6, upper bolts 28 are secured near the ends of the spanner bar 14a as by welding. This invention also contemplates use of turnbuckles in which the upper bolts are not immovably secured to the spanner bar.
The spanner bar 14a may exted only between two adjacent joist members, or it may be long enough to extend past three or four or more joists. Preferably the spanner bar 14a is long enough to extend slightly beyond the center lines of the two joists which support the ends of the spanner bar. For example, a spanner bar for extending between two joists which have centerlines 4 feet apart is preferably about 4 feet 2 inches to about 4 feet 4 inches long.
FIG. 7 is a sectional view of the top of a joist showing angle bars 4 and 6 of the upper chord of the joist and closure member 5 which prevents freshly-poured concrete from falling past the upper chord. Closure member 5 is an elongated member which extends between adjacent members of V-shaped portions of the open web.
While closure member 5 may be supported on angle bars 4 and 4 to some extent by spanner bars, it is configured so that the upper edges 7 and 9 press against the outer sides of the vertical legs of angle bars 4 and 6 as shown and retain closure member 5 in place by friction.
Closure member 5 may have other configurations, such as a U-shape, which are adapted to retention on the angle bars by engagement of the inner surface of the side walls of the closure member with the outer surfaces of the angle bars.
The material from which closure member 5 is made is not critical and either plastic or metal, for example, are suitable. In order to provide sufficient rigidity, longitudinal ribs may be provided in closure member 5, and the inner walls of the upper ends which are to bear against the angle bars may be provided with grooves or ridges to reduce the tendency of the closure member 5 to slip off.
As noted above, support 20 is particularly well-adapted for use with the closure member 5, or with the closure member described in Ser. No. 829,891, cited above, since it is entirely supported by the lower chord.
The foregoing is only intended to illustrate the invention and modifications and changes will readily occur to those skilled in the art.
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A support for a spanner bar in an open web bar joist system which is supported by a lower chord of the bar joist. The support includes a base member for securing the support to the lower chord, a first elongated vertical member which is affixed to the base member, and a second elongated member which is axially aligned with respect to the first member. Structure is provided for moving the second member axially with respect to the first member.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of and priority from U.S. Provisional Patent Application Ser. No. 60/387,185, entitled System and Method for Hydrogen-Rich Selective Oxidation, filed Jun. 6, 2002 which is incorporated herein by reference in it's entirety.
FIELD OF THE INVENTION
The present invention relates generally to semiconductor fabrication. More particularly, the present invention relates to a system and method for selective oxidation of device features on semiconductors or integrated circuits in a hydrogen rich environment.
BACKGROUND OF THE INVENTION
Fabrication of semiconductor devices or integrated circuits requires many complex steps. Heat treatment is an important step in the fabrication of semiconductor devices and is used to carry out a variety of processes such as thermal annealing and thermal oxidation, among many other processes.
As well known in the art, semiconductor devices are made of a number of conductive and insulating features on a semiconductor substrate. Devices such as gate electrodes comprised of a gate stack including layers of materials such as polysilicon, dielectric, and metals are commonly used. For semiconductor devices having a critical geometry requirement of less than 130 nm, the polysilicon layer may be strapped over the top by a metal silicide layer. However, it has been found that the circuit performance of such a device is limited due to resistance of the device to device interconnect lines. To reduce the resistance of these interconnect lines, it has been proposed in the industry to replace the metal silicide layer and to fabricate the interconnect lines of polysilicon strapped over the top by a barrier layer and then a metal layer which exhibits a lower resistance than the metal silicide layer, as illustrated in FIG. 1 .
Plasma etch processing is typically used to define the gate device. The plasma etch step leaves a roughened edge on the polysilicon layer and produces plasma induced damage near the gate dielectric layer at the bottom of the polysilicon layer. Such damage may cause device failure or degraded performance. Methods have been developed in an attempt to minimize such failure or degraded performance. Methods have been developed in an attempt to minimize such damage, and have included an oxidation step to form a thin oxide layer of approximately 5 to 15 nm thick on the sidewall of the polysilicon layer to repair the plasma damage caused in the plasma step.
It has been found however, that during this oxidation step used to repair the plasma damage, the oxygen-rich environment exposes the metal layer to attack and the oxidant can destroy the metal layer. To address this problem, selective oxidation processes have been investigated.
In one prior art approach, selective oxidation of gate electrodes having polysilicon and tungsten metal structures has been performed in single wafer reactors using a catalytic reactor which reacts hydrogen and oxygen to form partial pressure of water vapor in the reactor ambient. Such an approach suffers from disadvantages however, such as high cost of the catalytic reactor and low throughput (less than approximately 10 wafers per hour achievable by such a single wafer system).
Batch furnace systems have long been employed to carry out annealing processes in the fabrication of semiconductor wafers. Many batch annealing processes are carried out in a hydrogen environment (hydrogen anneal). In most annealing processes, hydrogen is diluted with nitrogen, and safety features such gas ratio interlocks are used to control the hydrogen to concentrations below the explosive or flammability limit. However, for some process applications annealing in an atmosphere of up to 100% hydrogen is required. Systems of this type incorporate use of circuits that force a timed nitrogen purge of the reactor or tube prior to the flow of hydrogen gas, and an automated post purge of nitrogen applied upon the termination of the flow of hydrogen gas. While this approach is useful, improvements are needed. Accordingly, improved systems and methods for selectively oxidizing one material with respect to another in the fabrication of semiconductor devices is desired.
OBJECTS AND SUMMARY OF THE INVENTION
It is a general object of the present invention to provide a system and method for selective oxidation of device features on semiconductors or integrated circuits in a hydrogen rich environment. In another aspect the present invention provides a system and method for selectively oxidizing one material with respect to another material on a semiconductor substrate or wafer, such as oxidizing polysilicon without oxidizing metal layers such as tungsten that are also present on the substrate.
In a further aspect, the present invention provides a hydrogen-rich oxidation system and method for performing selective oxidation in a batch thermal processing system in which safety features are included to avoid the dangers to personnel and equipment that are inherent in working with hydrogen-rich atmospheres.
In one aspect, the present invention provides a method of selectively oxidizing one material with respect to another material formed on one or more semiconductor substrates, comprising contacting the one or more substrates in a process chamber with an environment comprising approximately 10% to 30% steam and the balance hydrogen, at a temperature in the range of approximately 700 to 850° C. to form an oxide layer selectively on the one material.
In another embodiment present invention provides a system that includes a processing chamber. The processing chamber accommodates one or more substrates and is provided with a controllable gas flow system that supplies any or all of hydrogen, oxygen, nitrogen, or inert gases. A hydrogen-rich atmosphere is supplied to the processing chamber via a torch chamber. In the torch chamber, oxygen gas is reacted with hydrogen to produce steam. The substrate is selectively oxidized under the resulting steam and hydrogen ambient atmosphere. To facilitate safe operation of this system under hydrogen-rich conditions, a series of interlocks and dilution flow features are provided. A flame sensor is provided in the torch chamber to verify combustion of the oxygen-hydrogen mixture prior to its introduction to the processing chamber. A failure to detect ignition triggers an interruption of processing and inert gas is conveyed to the chamber at a high flow rate (also referred to as inert gas dilution flow) to dissipate potentially explosive concentrations of hydrogen. Likewise, a system power failure also triggers high flow rate inert gas dilution of the system. Downstream of the processing chamber, a “burn box” is provided to function as a hydrogen afterburner that destroys unreacted hydrogen that passes the processing chamber and torch without reacting. Additional interlocks are provided that interrupt hydrogen flow and/or trigger inert gas dilution if the system fails one or more leak and pressurization tests.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional objects and advantages of the invention will become apparent in reading the detailed description of the invention and the claims and with reference to the figures, in which:
FIG. 1 is a cross-sectional view of a partially fabricated semiconductor device showing a gate electrode stack structure.
FIG. 2 is a cross-sectional view of a partially fabricated semiconductor device showing a gate electrode stack structure which has been selectively oxidized according to one embodiment of the present invention.
FIGS. 3A and 3B are a schematic diagram of a selective oxidation system according to one embodiment of the present invention.
FIGS. 4A and 4B are a flow chart illustrating one embodiment of the method of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a system and method for selective oxidation of device features on semiconducts or integrated circuits in a hydrogen rich environment. More specifically, in one embodiment, one material is selectively oxidized with respect to another material, both materials being present on a semiconductor substrate or wafer.
Referring to FIG. 2 , a partially fabricated semiconductor device is shown. In this example a gate electrode stack 5 having side wall 6 is formed on a substrate as illustrated. Specifically the gate electrode is comprised of a substrate with a dielectric layer formed thereon. In this example the dielectric layer is formed of silicon dioxide. A polysilicon layer is formed atop the dielectric layer. A barrier layer, in this example a tungsten nitride material (WN) is formed atop the polysilicon layer. A metal layer is formed atop the barrier WN layer, and the metal layer is then capped. In this example the metal layer is formed of tungsten (W) and capped with silicon nitride (SiN).
Of particular advantage, the present invention provides for selectively oxidizing one layer or material in the gate stack with respect to another layer or material in the gate stack. Specifically, the side wall 6 region at the polysilicon layer is oxidized with a layer 7 of silicon dioxide, while the metal layer is not oxidized. This promotes lowering of the resistance of the device without damaging the metal layers in the device.
According to the present invention selective oxidation is carried out in a hydrogen rich environment. In general, semiconductor wafers are placed in a thermal processing chamber 12 (shown in FIGS. 3A and 3B and described in detail below). A hydrogen rich environment is created in the chamber 12 , and this environment may be up to 100% hydrogen. Oxidation is carried out by exposing the wafers to steam in the hydrogen rich environment. In one embodiment steam is present in the chamber at a concentration in the range of approximately 10% to 30% with the balance being hydrogen.
The steam is created by reaction of hydrogen and oxygen in the presence of a flame in a torch chamber (creating a pyrogenic steam generator).
In one embodiment, the system of the present invention provides a torch with the hydrogen and oxygen supply inlets interchanged. In addition, the torch includes a flame sensor. The furnace is fitted with a “burn-box” in which unreacted hydrogen is combusted. Finally a series of safety interlocks are added to enhance safe operation of the system.
Generally, in one embodiment the system 10 of the present invention as shown in FIGS. 3A and 3B includes a thermal processing or furnace chamber 12 (also referred to as a tube or process tube) equipped with a pressure differential sensor 14 ; a hydrogen burn box 16 equipped with a pressure differential photohelix 18 ; an exhaust tube 20 leading from the burn box to the facility exhaust; a torch 22 including an oxygen gas inlet 24 , a hydrogen gas inlet 26 (each oxygen and hydrogen inlets being coupled to respective gas cabinets, not shown), and a UV flame sensor 28 . Sealed tubing is provided as appropriate such as leading from nitrogen, hydrogen, and oxygen gas supplies to corresponding gas inlets; and sealed tubing and appropriate check valves and filters are provided between the torch and the furnace chamber, and between the furnace chamber and the burn box.
As illustrated in FIGS. 3A and 3B , the thermal processing chamber 12 is generically shown, and it should be understood by those of ordinary skill in the art that other configurations of thermal processing systems may be used. One example of a suitable processing chamber, among many others, is described in U.S. Pat. No. 6,005,225, which is incorporated herein by reference in its entirety.
In general, the current invention provides a hydrogen/oxygen pyrogenic steam generator that can turn on and off in a hydrogen rich ambient to provide a means of water vapor generation controlled by a process recipe, a system to measure the leak integrity of the seals of the process chamber and interlocks not part of the user controlled recipe to prevent hydrogen flow until that leak integrity test is passed, and a safety interlock system that automatically activates a means of extracting unreacted hydrogen from the tube and diluting it with nitrogen to below hazardous levels in the event of an electrical power failure. Also provided is a method and system for detecting the presence of a hydrogen flame in the hydrogen-rich atmosphere of the torch.
The system of the present invention provides a pyrogenic steam generator by way of the torch chamber that can be turned on and off in a hydrogen rich ambient atmosphere to provide a controllable source of high purity water vapor. In contrast to prior art systems that generate water vapor by combusting hydrogen under lean (oxygen-rich) conditions, The system of the present invention provides a high concentration of hydrogen to a hydrogen-oxygen torch and then controls oxygen flow to the combustion region to produce a small flame that generates water vapor.
In another embodiment of the present invention, a hydrogen/oxygen pyrogenic steam generator that can turn on and off in a hydrogen rich ambient to provide a means of water vapor generation controlled by a process recipe is provided.
A further embodiment of the present invention provides a system to measure the leak integrity of the seals of the process chamber and interlocks to prevent hydrogen flow until that leak integrity test is passed.
Yet another embodiment of the present invention provides a system that automatically activates in case of an electrical power failure during hydrogen processing to provide a means of extracting the unreacted hydrogen from the processing tube and diluting it with nitrogen to below hazardous levels. This safety tube purge and abatement system operates even in the absence of electrical power.
To create an oxidizing atmosphere to oxidize polysilicon without oxidizing layers of metals such as tungsten on the semiconductor substrate, the resultant flame of the present invention is much smaller and less intense than those normally produced by a standard hydrogen torch. As such, prior art systems are inadequate to verify combustion and provide feedback to a system controller that uncombusted hydrogen is not flowing freely into areas of the system in which is might form an explosive mixture. The present invention employs a sensitive sensor located closer to the torch combustion region. Its output is directly fed back to the system process controller as an interlock that if triggered will cause hydrogen flow to be shut off and high flow rate dilution with an inert gas such as nitrogen to be initiated.
In one embodiment the method of the present invention includes the following steps as illustrated in FIGS. 4A and 4B to selectively oxidize device features on one or more wafers or substrates loaded in a wafer support such as a boat or cassette (not shown). The boat is loaded with wafers in a nitrogen ambient under the process chamber 12 as shown in step 110 . An idling temperature of approximately 300–600° C. is established in the processing tube with nitrogen flowing at step 112 . The nitrogen gas flow is sufficient to purge oxygen and other contaminants from the process chamber. In one embodiment, the nitrogen flow is approximately 10 standard liters per minute (slm). The oxygen concentration in the chamber is checked at step 114 , and once the ambient atmosphere in the chamber is less than approximately 5 ppm oxygen, the boat supporting the wafers is inserted into the chamber 12 and the door is closed at step 116 . With the chamber door closed at step 118 , a test is executed to establish that the system is sealed with no major leaks such as, for example, would occur if the torch were disconnected. Once the door is closed, a nitrogen gas pre-purge is run through the processing chamber for approximately 10 minutes at step 120 . Then at step 122 hydrogen gas flows to the chamber is begun at approximately 10 to 20 slm and the chamber temperature is ramped to 800° C. at step 124 . After the temperature has stabilized with hydrogen flowing, oxygen gas flow to the torch is begun at step 128 . If the flame is not detected by the torch sensor 28 within a programmed period of time, the oxygen gas flow is stopped to avoid formation of a potentially explosive mixture on the processing chamber at step 128 . Steam created by the reaction of hydrogen with oxygen in a concentration of approximately 10% to 30% steam with the balance hydrogen flows through the processing chamber and selectively oxidizes polysilicon without oxidizing metals such as tungsten metal formed on top of the polysilicon material at step 130 . At the end of the selective oxidation step, the oxygen flow is shut off to terminate the generation of steam in step 132 . At step 134 hydrogen gas continues to flow into the processing chamber while the temperature is ramped down. Once the temperature at which the boat is to be removed from the processing chamber is reached, the tube 12 is post-purged with nitrogen gas at step 136 . The boat is pulled into a nitrogen ambient area under the tube for unloading of the wafers at step 138 .
When the boat is pushed into the chamber 12 , and the temperature in the process chamber is ramped up and stabilized at a temperature of 700 to 850° C. under a flow of nitrogen gas, and hydrogen flow is initiated during temperature stabilization; then a low flow rate of oxygen is initiated through the gas injector of the external torch 22 . A small flame is formed that can preferably be detected by an optical sensor as a safety interlock to verify that the reaction of oxygen with hydrogen to form steam is in process.
To avoid oxidation of tungsten or other metal layers in the wafers, it is essential that no free oxygen be introduced into the process tube, and it is preferable that the partial fraction of the steam generated by reaction of the oxygen with the hydrogen be maintained at less than approximately 20%, with hydrogen comprising the balance of the atmosphere in the chamber.
The polysilicon material on the wafer is allowed to oxidize until a surface oxide layer of 5 to 15 nm has developed. Under the high hydrogen ambient in the presence of steam but without any free oxygen the tungsten metal is not oxidized. The process is terminated by switching off the oxygen gas flow, purging the tube of steam using hydrogen, switching to nitrogen and ramping temperature down to the value (typically 600° C.) used for push and pull of the boat containing the wafer batch load. It is important that the ambient environment in the chamber and under the chamber be maintained at less than approximately 1 ppm oxygen until the wafers have cooled to below 200° C.
Referring more specifically to FIGS. 3A and 3B which shows a schematic diagram of one embodiment of the present invention, the following detailed description is provided. It should be understood by those of ordinary still in the art that other specific configuration and programmable logic routes and alarms may be employed within the scope of the teaching of the present invention. This specific description is provided for illustration and is not intended to limit the scope of the invention. The gas flow schematic and interlock system 30 , including associated valves, controller and the like, is generally shown in 3 FIGS. 3A and 3B . A field programmable gate array (FPGA, not shown) is a programmable integrated circuit device that can be used to program various outputs based on combinations of inputs. Programming of FPGAs is carried out by methods well known in the art. In the exemplary embodiment of the present invention, these inputs comprise valve commands from recipe control and alarm inputs from the system. FPGA outputs include qualified valve outputs to operate valves and qualified alarm outputs to the operating system. Safety of the system depends on the safety logic programmed into the FPGA and the redundant relay interlocks. A redundant relay interlock is provided as a the backup interlock system comprised of relay logic, employed in parallel with the FPGA. Its function is to interrupt power to selected solenoids in the event of a failure in the primary interlock system (FPGA and related electronics).
Hardware circuitry and firmware on the LCA board monitor for faults including whether the gas interface sub-system power supplies are out of tolerance, load faults in the programmable logic array configuration, detection of programmable logic array configuration corruption by the micro-controller auditor firmware, and general faults triggered by a process controller watchdog and a micro-controller Xilinx watchdog (Subsystem failure). These faults shut off power to hazardous gas valves and turn on an audible alarm as long as the condition exists. When the fault is cleared the gas valves will turn back on. These fault conditions are not latched.
In general, gas valves or automatic valves are valves located downstream from their associated mass flow controllers (MFCs). They are automatically given an ON command when a non-zero set point is sent to the MFC and they are automatically given an OFF command when a zero setpoint is sent to the associated MFC. As shown in FIGS. 3A and 3B , valves are identified with the same ID number as the associated MFC (for example, Valve 1 corresponds to MFC 1 , Valve 2 corresponds to MFC 2 , etc.). However, the ability of these valves to actually turn ON or OFF is individually controlled by interlock logic programmed within the FPGA.
Process valves or non-automatic valves generally control the process. This group includes all other valves in the gas system. They must be given an ON command via recipe control from the FPGA. However, like the automatic valves, the ability of these valves to actually turn ON or OFF is individually controlled by interlock logic programmed within the FPGA.
A gas system disabled (GSD) state occurs when power to selected gas valve solenoids and process control valve solenoids is removed. This is designed to be a safe state. A user interface is provided in this exemplary embodiment to indicate this state via sets of relay contacts. Certain alarms cause the system to enter this state. Once the tool enters this state it will remain in this state until the alarm causing the GSD has been cleared and the operator resets the system.
A valve is defined to be ‘ON’ if gas can flow through the valve. In the case of a normally open (N.O.) valve, the valve is ‘ON’ when the valve does not have power. Each valve in the gas system is controlled by a signal from the FPGA. Signals generated by the recipe are sent to the FPGA. The FPGA processes the signal by internal programmed logic. If interlock conditions are met, the FPGA outputs a signal to a valve driver to control the valve. Redundant shutoff is provided to selected valves by relay logic. There are four relay loops on the valve driver board that can be programmed to shut off selected valves. These loops are designated “A, B, C, and D”. In addition to the four relay loops on the valve driver board a non-interruptible fifth loop (E) is provided for those valves that do not require relay interruption of power.
When certain interlocks programmed in the FPGA device are violated the FPGA places the system in a latched GSD State. Upon entering this state, an audible alarm is sounded that may be silenced via a push-button switch located on the rear of the main unit, labeled “SILENCE ALARM”, or at the front panel by clicking the mouse on a software-displayed button on the CRT. The indicator in the “SILENCE ALARM” switch is then turned ON to indicate that the alarm has been silenced. Once the alarm-causing condition has been cleared, the system must be manually reset via a lighted “RESET GAS SYSTEM DISABLE” push-button switch also located on the rear of the main. In this exemplary embodiment unless otherwise specified, the following alarms always cause the tool to enter the GSD State: Gas Cabinet Exhaust Fault (Alarm 5 ), Element Exhaust Fault (Alarm 8 ), Cabinet Over Temperature (Alarm 10 ), Burn-off Exhaust Fault (Alarm 11 ), Gas Cabinet Door Open (Alarm 14 ), Element Removal (Alarm 33 ), External System Disable Request (Alarm 37 ), Nitrogen Pressure Low (Alarm 28 —if hydrogen is flowing). These alarms are discussed in greater detail in the succeeding paragraphs. Of course, other configuration and alarms may be employed within the scope of the invention.
Certain critical alarms are used to actuate relays as well as inputs to the FPGA. If one of these alarms become active, the associated relay de-energizes removing power from the selected valves to provide redundant shutoff. Most alarms that cause the FPGA to go into the GSD state are backed up by relays. Unless otherwise specified, the following GSD alarms are backed up by a hardware relay: Gas Cabinet Exhaust Fault (Alarm 5 ), Element Exhaust Fault (Alarm 8 ), Scavenger Exhaust Fault (Alarm 11 ), Gas Cabinet Door Open (Alarm 14 ), and Element Removal (Alarm 33 ). Unless otherwise specified, the Process Door Open (Alarm 6 ) and AC Power Fault (Alarm 32 ) alarms shut off the power to System Disable Valves by relay action and by FPGA logic without causing GSD State. The Element Door Open (Alarm 59 ) and Gas System Watchdog (Alarm 38 ) alarms interrupt power to System Disable Valves by relay action only.
All valves that enable a process gas considered hazardous to personnel or equipment are considered System Disable Valves. In this exemplary embodiment of the present invention, the following valves are Gas System Disable Valves: High Hydrogen (Valve 2 ), Low Hydrogen (Valve 4 ), Hydrogen Enable (Valve 12 ), Hydrogen Manifold Purge (Valve 9 —Normally Open Valve), Oxygen (Valve 3 ), and Oxygen Manifold Purge (Valve 11 —Normally Open Valve).
When a power monitor relay de-energizes due to the system losing AC Power, a power fail signal (Alarm 47 ) is sent to the Process Controller. This same Power Fail signal also triggers an approximately 30-second delay circuit. After the 30-second delay circuit has timed out an AC power fault (Alarm 32 ) is generated. Alarm 32 starts an approximately 120-second timer. During this approximately 120-second period, the system operating on uninterruptible power supply power saves critical data before going into a controlled shutdown. After the approximately 120-second timer times out, an EPO signal is generated and all power to the system is removed. However, should AC Power come “back up” before Alarm 32 becomes active, the system will not go into the EPO condition. In that case processing will continue as before power loss.
Logic within the FPGA provides a run-time signal to drive a gas hour meter for monitoring the primary process gas flow. In this system the process gas monitored is hydrogen (H2). The following conditions send a signal to the GHM:
High H2 (Valve 2 ) or Low H2 (Valve 4 ) and H2 Enable (Valve 12 ) must be on.
Two automatic nitrogen gas purges are included in this exemplary embodiment. A system disable or power down purge occurs if the system enters the system disable state or if system power is lost. A timed pre-processing purge occurs if hydrogen flow is enabled (Valve 12 ) and a timed post-processing purge occurs if hydrogen processing is interrupted for any reason. The hydrogen manifold is purged via ultra high purity nitrogen (Normally Open Valves 9 and 11 ) through a 10 slm flow restrictor. A purge of the hydrogen manifold by the two nitrogen valves described above begins immediately upon entering the gas system disabled state and continues unabated until the system is manually reset. At that time, when the system is reset, Valves 9 and 11 are energized into their normal non-flow states, ending the purge. This purge will occur in every case of Gas System Disabled state except that caused by N2 Pressure Low Alarm 28 as described below. If system power is lost, the normally open purge valves will open and the H2 manifold will purge indefinitely.
A timed pre-processing and post-processing inert gas purge is initiated at the beginning and end of a Gas System Disabled state caused by nitrogen Pressure Low (Alarm 28 ), while hydrogen gas is flowing. Additionally, these purges are initiated upon enabling hydrogen flow through Valve 12 . Purges are also commanded whenever hydrogen gas flow is interrupted for any reason during hydrogen processing. During timed pre-processing and post-processing purges, Alarm 36 (Elevator Disabled) is activated to disable the elevator mechanism. Alarm 19 (Pre/Post Purge). A status indicator will also be sent to the Process Controller. Purge valves 9 and 11 are de-energized to their flow states and a countdown of approximately 10 minutes starts. If, after the purge begins, and before it completes, a low nitrogen pressure alarm (Alarm 28 ) occurs, the purge countdown is suspended on each occurrence until the nitrogen pressure returns to a non-alarm level, and won't complete until a cumulative approximately 10 minutes of nitrogen purging has taken place. Alarm 19 will indicate constantly from the time that purge starts until the purge is completely finished, and the elevator will be disabled by Alarm 36 (Elevator Disabled). At the completion of pre-processing and post-processing purges and after the system disable alarm is reset, both Valves 9 and 11 are energized into their normal non-flow states.
The system includes a hydrogen burn box 16 that must be on when hydrogen gas is flowing. In the exemplary embodiment, the burn box contains dual igniters (igniter 31 and igniter # 2 ) that are powered from 120 volts AC and act as an “afterburner” to combust unreacted hydrogen before it is vented to the exhaust system. The main igniter (igniter # 1 ) is turned on by logic in the FPGA when the pre-processing purge begins and remains on until after the post-processing purge has completed. The burn box is also equipped with a redundant stand-by igniter (igniter # 2 ) which is activated if the igniter # 1 fails. Circuits in the burn box perform the switch over if this fault condition is detected. Valve 18 output is assigned as the bum box ON command. This valve can be turned on from the recipe for maintenance purposes. However if the ON command is generated from FPGA safety logic the recipe cannot turn off the burn box. Two Alarm outputs from the burn box report the integrity of the igniters. Alarm 12 indicates igniter # 1 is open and igniter # 2 is active. Alarm 13 indicates igniter # 2 is open and the burn box can no longer burn hydrogen. Alarm 13 aborts the hydrogen process and starts the post-processing purge.
Preferably, a pressure differential photohelix 16 located near the process tube monitors the pressure difference between the inside of the process chamber 12 and the outside pressure. Before hydrogen gas can flow, a leak test is preformed to check the integrity of the tube seal. In one example an automatic leak test is performed by logic in the FPGA upon closing of the process door. The operator initiates an automatic leak test by activating Valve 16 from the operator recipe if the tool is not processing or purging and the process door is closed. Automatic leak testing is performed by first opening Valve 27 for approximately 10 seconds to relieve any pressure in the tube. Then, Valve 16 is opened to enable the differential pressure sensor. The chamber exhaust flow is sealed off by closing Valves 26 and 27 . Next, Valve 10 is opened to allow nitrogen gas to flow to the chamber at the rate of approximately 1 slm through needle valve MV 10 . When a preset upper differential limit is reached as evidenced by Alarm 25 becoming active, Valve 10 is closed to stop the nitrogen gas flow. If Alarm 25 does not activate within approximately 3 minutes, the leak test fails and Alarm 7 is activated. The pressure differential is monitored for approximately 3 minutes. If the differential pressure stays above the preset lower limit, the test is passed. If the test fails, Alarm 7 is activated and remains on until the door is opened, the leak repaired and a retest of the door seal passes. At the end of the leak test, Valve 27 opens for approximately 10 seconds to equalize pressure in the processing chamber or tube. After the equalization period, Valve 16 closes, thus sealing off the differential pressure sensor.
In the exemplary embodiment, the temperature of the torch 22 must be greater than 750° C. before oxygen gas can flow. Alarm 1 (Torch Temperature Below 750° C.) functions as an oxygen process scenario start-up alarm only, and as such, has no effect once oxygen gas is flowing; the alarm then being “masked” (transparent to system operation) by FPGA logic. The torch temperature must remain in the range of approximately 350° C. to 900° C. while oxygen gas is flowing, otherwise oxygen gas flow will be turned off. Alarm 2 (Torch Temperature Between 350 and 900° C.) is a “masked” alarm. It is not be passed to the Process Controller for status, nor is it used for interlocks by the FPGA, unless oxygen and hydrogen gases are flowing. Once the alarm occurs, it is latched within the FPGA until a zero setpoint command is sent to the oxygen MFC.
In one exemplary embodiment, the flame detector 28 at the torch must detect a flame within 15 seconds after oxygen gas begins flowing, or else oxygen gas flow is forced off. Any loss of flame after initial ignition will cause an immediate activation of Alarm 3 (Flame Detect), shutting off oxygen flow as well. Alarm 3 is a “masked” alarm; meaning that it is not passed to the Process Controller for status, nor is it used for interlocks by the FPGA, unless oxygen and hydrogen gases are flowing. Once the alarm occurs, it is latched within the FPGA until a zero setpoint command is sent to the oxygen MFC.
Alarm 4 (Hydrogen/Oxygen ratio Less than 2.15) is activated if the ratio of hydrogen flow to oxygen flow is less than approximately 2.15:1. Alarm 4 is a “masked” alarm; meaning that it is not passed to the Process Controller for status, nor is it used for interlocks by the FPGA, unless oxygen and hydrogen gases are flowing. Once the alarm occurs, it is latched within the FPGA until a zero set point command is sent to the oxygen MFC.
Loss of gas cabinet exhaust for approximately 10 seconds as monitored by a photohelic sensor causes Alarm 5 (Gas Cabinet Exhaust Fault) to be generated. This alarm shuts off process gas flows and causes the system to enter the latched gas system disabled state.
Several alarms provide input to the FPGA. Alarm 6 (Process Door Open) becomes active when the process chamber door is open. If the chamber leak test described above is failed, Alarm 7 (Leak Test Failure) is activated. Detection of a fault in the facility exhaust triggers Alarm 8 (Facility Exhaust Faut) which is a GSD alarm backed up by a relay. Loss of element exhaust for approximately 10 seconds as monitored by the aforementioned photohelic sensor causes activation of Alarm 8 . This alarm shuts off process gas flow and causes the system to enter the latched gas system disable state. This alarm also turns on the nitrogen dilution valve (Valve 25 ) if hydrogen flow is on or if the tool is in the purge mode. Once facility exhaust is restored and Alarm 8 is deactivated, Valve 25 turns off, stopping the nitrogen dilution flow. The tool remains in the GSD state until the operator resets the tool. Detection of hydrogen gas by a sensor causes Alarm 9 (Hydrogen Leak Detect) to become active. This alarm shuts off hydrogen and oxygen gas flows. Three hydrogen sensors are located in the gas cabinet, above the torch and in the upper cabinet. These sensors are configured to generate Alarm 9 if any sensor detects hydrogen. These sensors are set to detect 25% of the lower explosive limit for hydrogen. If a temperature sensor in the top of the main cabinet detects a temperature greater than approximately 62° C., Alarm 10 (Cabinet Over Temperature) is activated. This alarm shuts off process gas flow and causes the system to enter the latched Gas System Disable State. Loss of burn-off exhaust for approximately 10 or more seconds as monitored by the aforementioned photohelic sensor generates Alarm 11 (Burn-Off Exhaust Fault). This alarm shuts off process gas flow and causes the system to enter the Gas System Disable State. Alarm 12 (Burn-Off Igniter # 1 Fault) becomes active if igniter # 1 opens. If this alarm is activated before hydrogen processing is initiated, hydrogen flow through Valve 2 is inhibited. If Alarm 12 becomes active after hydrogen processing has begun, hydrogen flow is not affected. Under this condition, the alarm is merely advisory. The alarm is masked until approximately 5 seconds after initial turn on of the bum box. Once active, Alarm 12 remains on until the hydrogen enable valve (Valve 12 ) is commanded off by recipe.
Alarm 13 (Burn-Off Igniter # 2 Fault) becomes active if igniter # 2 opens. This alarm aborts hydrogen processing and starts a timed post-processing purge with nitrogen gas. This alarm is masked for approximately 5 seconds after Alarm 12 becomes active to allow for igniter switch over and heat up. Once active, Alarm 13 remains on until the hydrogen enable valve (Valve 12 ) is commanded off by the recipe. When the gas cabinet door is open Alarm 14 (Gas Cabinet Door Open) becomes active. This alarm shuts off process gas flows and causes the system to enter the latched Gas System Disable State. Alarm 16 (Low Water Flow) occurs if the water flow falls below the preset minimum flow rate. This alarm is advisory only and is not used to interlock valves. Alarm 18 (Nitrogen Dilution Pressure Low) is active if the facility environmental nitrogen source pressure measured by PT 10 is below approximately 60 psig. Alarm 18 is used as an hydrogen process scenario start-up alarm only. Once hydrogen gas is flowing the alarm is then advisory only. Alarm 19 (Timed Pre/Post Purge) occurs if the system goes into a timed automatic purge as described above. This alarm remains on until a cumulative approximately 10 minutes of purging with nitrogen gas has completed. This alarm triggers Alarm 36 which disables the elevator. It also forces valves 9 , 11 and 27 ‘ON’ in addition to forcing on the burn box valve (Valve 18 ).
If the system goes into the gas disabled state, Alarm 20 (Gas System Disable) becomes active. Alarm 21 (Leak Test) becomes active during the Leak Test and remains on until Leak Test has completed. It is an advisory alarm only. Other masked and/or advisory alarms are discussed below. Alarm 22 (MFM 10 (N2) FLOW<1 slm) becomes active if Valve 10 is on and the nitrogen gas flow through the loop is less than 1 slm. It is a masked advisory alarm. Alarm 24 (Burn Off IR Sensor Fault) is also masked. It becomes active if the temperature of the hydrogen burn-off igniters falls below the preset limit. This alarm is masked until 10 seconds after the burn off is commanded on. If while the process door is closed the differential pressure between the process chamber and the outside exceeds the preset upper limit Alarm 25 (Differential Pressure High) is activated. If this alarm occurs all gas flow into the tube is shut off to prevent over-pressuring the tube. Alarm 26 (High Hydrogen Flow) occurs if hydrogen gas flow via MFC 2 exceeds 90% of full scale flow. Alarm 26 is a “masked” alarm. It is passed to the Process Controller for status, nor will it be used for interlocks by the FPGA, unless hydrogen gas is flowing. This alarm is advisory only and is not used to interlock valves. Alarm 27 (Pneumatic Pressure Low) becomes active if the pneumatic pressure is less than 60-psig+5 psig as measured by a pressure switch in the pneumatic line.
Alarm 28 (Nitrogen Pressure Low) is a conditional alarm that becomes active if the nitrogen gas line purge pressure is below 10-psig-+5 psig as measured by pressure transducer PT 1 . If hydrogen gas is flowing or if the system is purging at the time this alarm becomes active, the system enters the GSD state. At that time all process gases are shut off and the elevator is disabled. Alarm 29 (Hydrogen Pressure High) becomes active if hydrogen pressure is more than 60 psig as measured by pressure transducer PT 2 . This alarm aborts hydrogen processing.
Alarm 30 (Oxygen Pressure Low) becomes active if oxygen pressure is less than 12 psig as measured by pressure transducer PT 3 . Alarm 32 (AC Power Fault) is activated when AC input power is lost for more than approximately 30 seconds+5 seconds. This alarm shuts off process gas flows and seals off tube. Alarm 33 (Element Removal) is a GSD alarm backed up by a relay that is activated when the chamber is moved from its normal processing position. This alarm shuts off process gas flows and causes the system to enter the gas system disable state.
Alarm 34 (Hydrogen Flowing) is an advisory alarm activated when hydrogen is flowing through MFC 2 . This alarm is advisory only and is not used to interlock valves. Alarm 35 (Torch Shield Open) becomes active if the torch shield is open. Alarm 36 (Elevator Disable) is a reporting alarm only with no interlocks and is generated by the logic within the FPGA when hydrogen gas is flowing and/or during the timed nitrogen pre-processing and post-processing purges. Alarm 37 (External Gas System Disable Request) is a GSD Alarm generated by the operator and routed to the tool via the operator I/O panel. This alarm shuts off process gas flows and causes the system to enter the latched gas system disable State as defined above. It functions as a manual override for emergency shutdown of the system by the operator.
A gas system watchdog circuit (Alarm 38 ) located on the LCA board monitors the integrity of the process controller. This circuit monitors a periodic signal sent by the process controller. If the circuit fails to receive this signal within approximately 10 seconds, a watchdog alarm is generated. This alarm disables a relay and shuts off GSD valves. This alarm is not latched.
Finally, Alarm 59 (Element Door Open) becomes active when the heater door is opened. This alarm disables a relay and shuts off GSD valves. This alarm is not latched.
EXPERIMENTAL
For initial process testing, the flame detection feature of the standard oxidation system was bypassed and door sealing was verified by manual inspection and use of a portable handheld hydrogen monitor. This testing revealed the need for a method to verify chamber sealing before hydrogen is turned on. In addition, a required safety feature to be added was identified: in the event of a power outage, the system should purge the tubing and chamber of hydrogen to avoid the possibility of formation of an explosive mixture. Finally, tests showed that the small flame generated by the low process oxygen flow was not detected by the standard thermal oxidation flame sensor and a change was needed to enable flame detection to be used as a system safety interlock in the selective oxidation process.
The solutions developed for these three design issues are novel features which contribute to system safety for the hydrogen rich oxidation system and are described in greater detail below. The exhaust line from the tube is equipped with a valve. Upon sensing the closure of the process tube door, the firmware initiates an automated sequence in which the exhaust line valve is closed to prevent outflow of gas. Then valves controlling a flow of nitrogen into the tube through a fixed orifice restrictor are opened until the internal pressure is sensed to have reached a certain level. Next, the nitrogen valves are closed and a timed test period is begun. The pressure is monitored in the tube during the test period to verify that it remains above a lower threshold pressure throughout the test period. The time and lower pressure level are selected to detect leaks from seals or damaged parts. This period is typically 30 seconds, but other periods are acceptable. Hydrogen flow to the process chamber is enabled only upon passing of this pressure test.
In the case of a power failure, the exhaust valve from the tube is closed and a valve opened to a bypass which is connected by a “Tee” to a source of high flow nitrogen. The high flow nitrogen dilutes the hydrogen and steam in the tube to concentrations below the flammability limits (<4% H2) and the mixed gas (forming gas) is exhausted into the process gas exhaust duct supplied by the building in which the system is installed. This prevents accumulation of hydrogen at potentially flammable or even explosive levels if a system power failure occurs.
The standard flame detector is sensitive to UV radiation coming from an area approximately 2 inches downstream of the tip of the gas injector. By modification of the water cooled housing, the mounting angle of the UV detector was changed so it sensed the area nearer the tip of the injector and became usable for the selective oxidation process which only produces a small flame size.
As taught by the foregoing description and examples, a system and method of selectively oxidizing semiconductor wafers and other substrates in a hydrogen-rich atmosphere is provided by the present invention. The foregoing description of specific embodiments and examples of the invention have been presented for the purpose of illustration and description, and although the invention has been illustrated by certain of the preceding examples, it is not to be construed as being limited thereby. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications, embodiments, and variations are possible in light of the above teaching. It is intended that the scope of the invention encompass the generic area as herein disclosed, and by the claims appended hereto and their equivalents.
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The present invention relates generally to semiconductor fabrication. More particularly, the present invention relates to system and method of selectively oxidizing one material with respect to another material formed on a semiconductor substrate. A hydrogen-rich oxidation system for performing the process are provided in which innovative safety features are included to avoid the dangers to personnel and equipment that are inherent in working with hydrogen-rich atmospheres.
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FIELD OF THE INVENTION
[0001] The present invention relates to a novel protein useful as a selectable marker and corresponding polynucleotides for insertion of genes and other genetic material into a variety of organisms, including plants.
BACKGROUND OF THE INVENTION
[0002] Selectable markers are genes that impart a characteristic to an organism to see the results of a biochemical or chemical assay or test. Such markers are known as labels. One of the basic principles of recombinant DNA technology is the use of biological markers to identify cells carrying recombinant DNA molecules. In bacteria, these are commonly drug resistance genes. In bacteria, drug resistance is used to select bacteria that have taken up cloned DNA from the much larger population of bacteria that have not. For example, a commonly used marker in mammalian cells is a bacterial drug-resistance gene that confers resistance to a neomycin-related drug, G418, which kills mammalian cells by blocking protein synthesis. The marker gene encodes an enzyme that destroys the drug. Although numerous markers exist for bacterial and mammalian cells, fewer gene markers are available for organisms such as plants. It would be desirable to provide a gene marker that could enable one to differentiate between plants that carry particular recombinant DNA molecules from plant that do not.
SUMMARY OF THE INVENTION
[0003] In one embodiment, the present invention is directed towards a nucleic acid sequence comprising a polynucleotide encoding a protein comprising the amino acid sequence of SEQ ID. NO. 1. The nucleic acid sequence may be selected from the group consisting of SEQ ID NOS. 2, 3 and 4.
[0004] In another embodiment, the present invention is directed toward a DNA construct comprising a nucleic acid sequence comprising a polynucleotide encoding a protein comprising the amino acid sequence of SEQ ID. NO. 1.
[0005] In another embodiment, the present invention is directed towards a plasmid comprising a nucleic acid sequence comprising a polynucleotide encoding a protein comprising the amino acid sequence of SEQ ID. NO. 1.
[0006] In another embodiment, the present invention is directed towards a eukaryotic cell comprising a nucleic acid sequence comprising a polynucleotide encoding a protein comprising the amino acid sequence of SEQ ID. NO. 1. The eukaryotic cell can be a plant cell, such as a dicot plant cell or a monocot plant cell.
[0007] In another embodiment, the present invention is directed toward a plant or plant part having a eukaryotic cell comprising a nucleic acid sequence comprising a polynucleotide encoding a protein comprising the amino acid sequence of SEQ ID. NO. 1.
[0008] In another embodiment, the present invention is directed toward seed that can produce a plant comprising a nucleic acid sequence comprising a polynucleotide encoding a protein comprising the amino acid sequence of SEQ ID. NO. 1. The present invention is also directed towards seed from the plant of this embodiment.
[0009] In another embodiment, the present invention is directed toward a method of conferring resistance to the antibiotic nourseothricin, comprising providing to an organism t a nucleic acid sequence comprising a polynucleotide encoding a protein comprising the amino acid sequence of SEQ ID. NO. 1.
[0010] In another embodiment, the present invention is directed toward a protein either comprising or consisting of the amino acid sequence of SEQ ID. NO. 1. The protein can be in an isolated or non-isolated form.
[0011] In another embodiment, the present invention is directed towards a eukaryotic cell that can express a protein either comprising or consisting of the amino acid sequence of SEQ ID. NO. 1.
[0012] In another embodiment, the present invention a plant or plant part having a eukaryotic cell that can express a protein either comprising or consisting of the amino acid sequence of SEQ ID. NO. 1.
[0013] In another embodiment, the present invention is directed towards seed that can produce a plant comprising a protein either comprising or consisting of the amino acid sequence of SEQ ID. NO. 1.
[0014] In any of the above embodiments, the eukaryotic cells, plant or plant part can be from an organism such as a microorganism or a plant, such as a dicot plant, e.g. Arabidopsis thaliana or a monocot plant, e.g. Oryza sativa.
DETAILED DESCRIPTION OF THE INVENTION
[0015] This invention describes the use of a novel nourseothricin N-acetyltransferase (NRG) with the aminoacid sequence SEQ. ID No. 1, encoded by a novel nucleotide sequence as exemplified, but not limited to SEQ. ID Nos. 2, 3 and 4, useful as a selectable marker in an organism such as microorganisms and plants. The conditions for its use as selectable marker with rice and Arabidopsis thaliana are described herein.
[0016] Unless otherwise defined, 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.
[0017] Ag7 term—the Ag7 terminator sequence is a sequence of 213 nucleotides from the 3′ end of the gene number 7 from Agrobacterium tumefaciens. The sequence is derived from plasmid vector pGPTV-HPT as described by Becker et al. in 1992 (Plant Mol Biol 20:1195-1197).
[0018] aph4—selectable marker gene for hygromycin resistance. The sequence is derived from plasmid vector pGPTV-HPT as described by Becker et al. in 1992 (Plant Mol Biol 20:1195-1197).
[0019] AvrII refers to a restriction enzyme site.
[0020] “clonNAT” is the dihydrogen sulphate of the weakly basic antibiotic nourseothricin, consisting of streptothricin components F and D. The chemical name is 2-[4-O-Carbamoyl-2-deoxy-2-(3,6-diaminohexan-amido)-B-D-gulopyranoslamino)-3,3a,5,6,7,7a-hexahydro-5-hydroxy-4H-imidazo[4,5-c]pyridin-4-one dihydrogensulphate. The structural formula is set forth as follows:
[0021] GUS Intron refers to the GUS marker gene containing an intron, as disclosed in plamids pPG361 and pPG363.
[0022] HindIII refers to a restriction enzyme site.
[0023] nos prom—a promoter sequence from the nopaline synthase gene of Agrobacterium tumefaciens, as disclosed in plasmids pPG354, pPG361, pPG362, pPG363.
[0024] nos term—a terminator sequence from the nopaline synthase gene of Agrobacterium tumefaciens, as disclosed in plasmids pPG354, pPG361, pPG362, pPG363.
[0025] “Nourseothricin” refers to the streptothricin antibiotic components F and D, produced in cultures from a strain of Streptomyces noursei.
[0026] “nrg gene” refers to a generic group of nucleic acid sequence that can encode for the NRG protein. Selected species of the genus include, but are not limited to, nrg1, nrg2 and nrg3 described herein.
[0027] “NRG protein” or “Nourseothricin Resistance Gene protein” refers to the polypeptide or amino acid sequence of SEQ ID. NO. 1. This protein has the ability to confer resistance to the antibiotic known as nourseothricin.
[0028] 35S prom—a promoter sequence from the genome of cauliflower mosaic virus, as disclosed in plasmids pPG361 and pPG363.
[0029] ocs LB or “Left Border” refers to the DNA sequence that flanks the “left end” of the T-DNA and is disclosed in pPG361 and pPG363. The ocs LB is derived from octopine synthase (ocs) tumor inducing plasmids of Agrobacterium tumefaciens.
[0030] ocs RB or “Right Border” refers to the DNA sequence that flanks the “right end” of the T-DNA and is disclosed in pPG361 and pPG363. The ocs LB is derived from octopine synthase (ocs) tumor inducing plasmids of Agrobacterium tumefaciens. The osc RB and osc LB are recognized by Agrobacterium as sites for “cutting” or excision to enable the T-DNA to be inserted into a plant cell.
[0031] PmII refers to a restriction enzyme site.
[0032] The microorganism can be, for example, a fungus or bacteria. Where the organism is a fungus, the fungus can be from, but not limited to, any of the following genera: Magnaporthe, Mycosphaerella, Candida, Botrytis, Saccharomyces, Aspergillus, Peronaspora, Sclerotinia, Rhizoctonia, Phythium, Puccinia, Erysiphe, Ustilago, Fusarium, Phytophthora and Penicillium. Where the organism is a bacteria, the bacteria can be from Agrobacterium, Escherichia, Xanthomonas, Staphlococcus, Pseudomonas, Streptomyces and Bacillus.
[0033] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the present invention, and is not intended to limit the scope of the invention.
EXAMPLE 1
Preparation of the nrg Gene and Protein
[0034] Using the nat1 gene as the starting material from the plasmid pINS1, as delivered from the Hans Knoell Institute, the nrg gene is obtained in a PCR reaction, using the following primers:
[0035] forward primer: 5′nat1 HindIII; ccgaagcttATGACCACTCTTGACGACACG [SEQ ID NO. 5]
[0036] reverse primer: 3′nat1 AvrII; aaccctaggCTAGGGGCAGGGCATGCTCATG [SEQ ID NO. 6]
[0037] These primers add a HindIII or a AvrII restriction site right upstream, or downstream of the coding region of the nat1 gene, respectively. The PCR products of two independent reactions are cloned into a pUC vector derived plasmid (pPG354, digested with HindIII and AvrII), adding a nos promoter and a nos terminator upstream, and downstream of the nat1 gene, respectively. The resulting plasmid is called pPG362. The resultant gene is sequenced in the resulting plasmid pPG362 [SEQ ID NO. 7], sequencing three plasmid clones, derived from two independent PCR reactions. Surprisingly and unexpectedly, the sequence of all three clones yields the following new resultant gene, hereafter called the nrg2 gene (SEQ ID NO. 3), with following three nucleotide changes: the nucleotide cytosine (“C’) is replaced with adenine (“A”) at position at position 209, the nucleotide guanine (“G”) is replaced with guanine (“G”) adenine (“A”) at position 569 and the nucleotide adenine (“A”) is replaced with guanine (“G”) at position 570. Also surprisingly and unexpectedly, in the resultant NRG protein, the amino acid, glycine (A), is replaced with arginine (D) at position 70 in the protein or polypeptide sequence. Also surprisingly and unexpectedly, the new NRG protein retains the ability to impart resistance to the nourseothricin antibiotic.
EXAMPLE 2
Cloning the nrg gene into a binary vector
[0038] The nrg gene, controlled by the nos promoter and nos terminator elements from pPG362, is further cloned as a PmII fragment into the PmII sites of the binary vector pPG361, replacing the aph4 expression cassette, to give the new vector, pPG363, a binary vector containing the nrg expression cassette. In addition to the nrg expression cassette, the pPG363 plasmid [SEQ ID NO. 8] contains pRi Agrobacterium elements, ColEI elements for replication in E. coli, a kanamycin resistance gene, octopine-type left and right T-DNA border elements, and a GUS gene with an intron, controlled by the CaMV 35S promoter and the Ag7 terminator, as presented below. The description of the plasmid pPG363 is provided below and as SEQ ID NO. 8:
[0039] wherein the ocs LB, PmI I, nos prom, nrg, nos term, 35S prom, GUS Intron, Ag7 term, ocs RB are known in the art or described herein. The numbers in parentheses indicate the nucleotide position within the plasmid at which the respective restriction enzymes cut the plasmid DNA.
EXAMPLE 3
Rice Transformation Using a Binary Vector with the nrg Marker Gene
[0040] a) Dose response. For selection of transgenic calli based on resistance to clonNAT following Agrobacterium-mediated transformation of rice callus material, a dose response experiment is made to determine the concentration of clonNAT in callus growth medium in order to inhibit the growth of rice callus, or to kill the rice cells. Growth media (GM) used for rice callus comprise the following basic components: N6 salts (Duchefa) 3.95 g/l; B5 vitamins (Duchefa) 112 mg/l; proline (Duchefa) 500 mg/l; glutamine (Duchefa) 500 mg/l; casein hydrolysate (Duchefa) 500 mg/l. For the dose response experiment, medium plates are prepared that contain, apart from the basic components (GM), the following components: 2,4-D (2,4-dichlorophenoxyacetic acid; Duchefa) 2 mg/l; maltose (Sigma) 30 g/l; cefotaxime 200 mg/l; agarose (type I, Sigma) 5 g/l; pH 5.6. Medium plates are prepared with 25 ml of filter-sterilized medium per 10 cm petridishes. Variable amounts of a clonNAT stock solution of 200 mg/ml in water is added to these plates before filter-sterilization to obtain medium plates with clonNAT concentrations of 0, 5, 20, 100, 500, 1000 mg/l. Several pieces of rice callus, derived from immature rice embryos of the variety TP309 (National Small Grain Collection, USDA, ARS, Aberdeen, Id.) are put on these plates, the plates are incubated at 26° C. in the dark, and survival of the embryos and proliferation of the embryo cells are observed every day. Based on the survival rate of the embryos on the media plates containing different concentrations of clonNAT, a useful concentration of clonNAT for selection of transgenic rice is determined to be within a range of about 20 to about 1000 mg/l or more, preferably about 200 mg/l or less.
[0041] b) Agrobacterium Transformation. For Agrobacterium-mediated rice transformation, the pPG363 plasmid is electroporated into electroporation-competent Agrobacterium cells of the strain LBA4404 (Life Technologies) and the electroporated cells are plated on LB medium (10 g/l Bactopeptone (Difco), 5 g/l Yeast Extract (Difco), 5 g/l NaCl, 15 g/l Bactoagar (Difco), 50 mg/l kanamycin; pH 7.0) and are incubated at 30° C. Two days after electroporation, a colony is picked from the LB plate and is used to inoculate 5 ml of liquid LB medium (LB medium without Bactoagar). The 5 ml culture is incubated at 30° C. on a shaker at 200 rpm. After 16 hours, 0.05 ml of this 5 ml culture is transferred to 100 ml of liquid LB medium and is then incubated at 30° C. on a shaker at 200 rpm. After 16 hours, the bacteria cells are spun down by centrifugation at 3000 rpm, resuspended in 100 ml of induction medium (GM basic medium with 2,4-D 2 mg/l; 10 g/l glucose; 120 g/l maltose; pH 5.2), and incubated at room temperature on a shaker at 100 rpm. After 1 hour, rice immature embryos that are cultured on GM plates for 6 days after isolation are immersed in the bacteria suspension. After 20 minutes, the embryos are transferred to cocultivation medium plates (GM basic medium with 2,4-D 2 mg/l; 10 g/l glucose; 120 g/l maltose; 50 g/l agarose; pH 5.2) and are incubated for 3 days at 24° C. in the dark. The cultivated embryos are transferred to growth medium (GM) plates (GM basic medium with 2,4-D 2 mg/l; maltose 30 g/l; cefotaxime 400 mg/l; agarose 5 g/l; pH 5.6) and incubated at 26° C. in the dark. After 5 days the cultivated embryos are transferred to a selection medium, known as clonNAT200 selection plates (GM basic medium with 2,4-D 2 mg/l; maltose 30 g/l; cefotaxime 200 mg/l; clonNAT 200 mg/l; agarose 5 g/l; pH 5.6) and are incubated at 26° C. in the dark. After 4-5 weeks, colonies of clonNAT-resistant callus are growing from the pieces of embryo-derived callus that died on the clonNAT-containing medium plates. These resistant callus colonies are picked from these plates and are transferred to fresh selection medium with increased maltose concentration (clonNAT200 6%M, GM basic medium with 2,4-D 2 mg/l; maltose 60 g/l; cefotaxime 200 mg/l; clonNAT 200 mg/l; agarose 5 g/l; pH 5.6). Small parts of the isolated callus colonies are used in a histological GUS assay to test for GUS activity. Positive GUS staining is a direct indication that these callus pieces are transgenic (and have been selected on clonNAT selection) with the nrg resistance gene. After 10 days, the resistant calluses are transferred to fresh medium of same composition to increase the callus mass. After 1 week, the callus is transferred to regeneration medium (GM basic medium with maltose 20 g/l; sorbitol 30 g/l; NAA (naphtalene acetic acid) 0.5 mg/l; BAP (6-benzylaminopurine) 3 mg/l; agarose 8 g/l; pH 5.6) and these plates are incubated at 25° C. under 16 hours light. After 4 weeks, small regenerated plantlets are then transferred to rooting medium (½-strength MS (Murashige & Skoog) medium (micro and macro elements and vitamins), 2% sucrose, 0.15% phytagel (Sigma); pH 5.6) and grown to a height of 5-10 cm. Such plants are transferred to soil and are grown to maturity in the greenhouse. The transgenic state of these plants is tested by performing a histological GUS assay with leaf tissue, and a Southern analysis with plant genomic DNA probing with the nrg resistance gene.
EXAMPLE 4
Arabidopsis thaliana Transformation with the nrg Marker Gene
[0042] a) Dose response. The selection conditions for plants that are transgenic with the nrg gene are determined in a dose response experiment. From about 2000 to 3000 wildtype Arabidopsis thaliana seeds per pot are sown in 5″×5″ (13 cm×13 cm) soil pots. When the first true leaves of the seedlings have emerged after approximately 7 days, the seedlings are sprayed with a hand-held sprayer until all leaf material is completely wet on three consecutive days with a solution of 0.005% Silwet L-77 (50 ul/l) in water and variable concentrations of clonNAT (1, 5, 10, 20, 50, 100, 250, 500 mg/l). The results are assessed 36 hours after the last spray. A useful range of concentration of clonNAT for selection of transgenic Arabidopsis plants (as assessed as concentrations that kill non-transgenic Arabidopsis plants after applying the described sprayings) is determined within a range of about 20 to about 1000 mg/l or more, preferably about 200 mg/l or less.
[0043] b) Arabidopsis thaliana transformation. The binary plasmid pPG363 is transformed into Agrobacterium tumefaciens strain, GV3101, and the transformed cells are plated on LB medium (10 g/l Bactopeptone (Difco), 5 g/l Yeast Extract (Difco), 5 g/l NaCl, 15 g/l Bactoagar (Difco), 50 mg/l kanamycin; pH 7.0) and are incubated at 30° C. Two days after transformation, a colony is picked from the LB plate and is used to inoculate 5 ml of liquid LB medium (LB medium without Bactoagar). The 5 ml culture is incubated at 30° C. on a shaker at 200 rpm. After 16 hours, 0.05 ml of this 5 ml culture is transferred to 100 ml of liquid LB medium and is then incubated at 30° C. on a shaker at 200 rpm. For Agrobacterium-mediated transformation of the T-DNA containing the nrg gene and the GUS gene from pPG363 to Arabidopsis thaliana via a flower dipping protocol (Clough S J, Bent A F, Floral dip: a simplified method for Agrobacterium-mediated transformation of Arabidopsis thaliana. Plant J 1998 Dec;16(6):735-43), the primary bolts of about five-weeks old Arabidopsis thaliana plants are removed. Five days later, subsequently emerged secondary bolts have grown. The leaves and bolts of these plants are dipped or submerged for five minutes in a suspension, consisting of 30 ml of an over-night culture of Agrobacterium tumefaciens (ecotype GV3101, containing the binary vector pPG363) in LB medium, diluted 3-fold with a 5% sucrose solution containing 0.005% Silwet L-77. The dipped plants are then kept for over-night in the dark at 22° C. and are then transferred back to a location in the growth room were they grow to maturity under normal growth conditions. The T1 seed is harvested and then used for selection. 2000-3000 seeds are sown on a 5″×5″ pot filled with soil and are stratified for 2 days at 4° C. The pots are then transferred to the growth room with 16 hours light and 22° C. The seedlings are sprayed with a solution containing 0.005% Silwet L-77 and 200 mg/l clonNAT on three consecutive days when the first true leaves have emerged. Surviving seedlings are transferred to individual pots one week after selection and are grown to maturity under normal growth conditions. The transgenic state of the plants and their progenies is tested by performing a histological GUS assay using leaf tissue and by performing Southern analysis using genomic DNA isolated from the Arabidopsis plants and probing the DNA blots with a labelled probe from the nrg gene.
Preparation of Starting Materials
[0044] Origin, cloning, and sequence of the starting materials for preparing the nrg gene. The nat1 gene starting material is obtained from the Hans Knoell Institute, Jena, Germany, in plasmid pINS1. The sequence of the nat1 gene is described as the sequence X73149.1 (emb|X73149.|SNNAT1 S. noursei gene for nourseothricin acetyltransferase) found in the database at the National Center for Biotechnology Information (NCBI).
[0045] The binary vector pPG363 (SEQ ID. NO. 8) can be prepared from the vectors pPG361 (SEQ ID NO 9) and pPG362 (SEQ ID NO. 7).
[0046] Methods for preparing DNA constructs or plasmids is known in the art. See, e.g., Sambrook et al., Molecular Cloning: A Laboratory Manual (1989). The description of the plasmid pPG361 is provided below and as SEQ ID NO 9:
[0047] wherein ocs LB, nos term, aph4, nos prom, 35S prom, GUS Intron, Ag7 term, ocs RB, and PmII are known in the art or as described herein. The numbers in parentheses indicate the nucleotide position within the plasmid at which the respective restriction enzymes cut the plasmid DNA.
[0048] The description of the plasmid pPG362 is provided below and as SEQ ID NO 7:
[0049] wherein the nos prom, the nrg gene, the Nos term, and PmII are known in the art or described herein. The numbers in parentheses indicate the nucleotide position within the plasmid at which the respective restriction enzymes cut the plasmid DNA.
[0050] Plasmid pPG362 (SEQ ID NO 7) can be prepared from plasmid pPG354 and the nrg gene, as derived in a PCR reaction, by cloning the nrg gene PCR product as HindIII, AvrII-fragment into the HindIII and AvrII restriction sites of pPG354, replacing the aph4 gene.
[0051] The description of the plasmid pPG354 is provided below and as SEQ ID NO 10:
[0052] wherein nos term, aph4, nos prom, PmII, HindIII, and AvrII are as known in the art or as described herein. The numbers in parentheses indicate the nucleotide position within the plasmid at which the respective restriction enzymes cut the plasmid DNA.
1
10
1
189
PRT
Artificial Sequence
Novel protein conferring resistance to the
antibiotic known as nourseothricin
1
Met Thr Thr Leu Asp Asp Thr Ala Tyr Arg Tyr Arg Thr Ser Val Pro
1 5 10 15
Gly Asp Ala Glu Ala Ile Glu Ala Leu Asp Gly Ser Phe Thr Thr Asp
20 25 30
Thr Val Phe Arg Val Thr Ala Thr Gly Asp Gly Phe Thr Leu Arg Glu
35 40 45
Val Pro Val Asp Pro Pro Leu Thr Lys Val Phe Pro Asp Asp Glu Ser
50 55 60
Asp Asp Glu Ser Asp Asp Gly Glu Asp Gly Asp Pro Asp Ser Arg Thr
65 70 75 80
Phe Val Ala Tyr Gly Asp Asp Gly Asp Leu Ala Gly Phe Val Val Val
85 90 95
Ser Tyr Ser Gly Trp Asn Arg Arg Leu Thr Val Glu Asp Ile Glu Val
100 105 110
Ala Pro Glu His Arg Gly His Gly Val Gly Arg Ala Leu Met Gly Leu
115 120 125
Ala Thr Glu Phe Ala Arg Glu Arg Gly Ala Gly His Leu Trp Leu Glu
130 135 140
Val Thr Asn Val Asn Ala Pro Ala Ile His Ala Tyr Arg Arg Met Gly
145 150 155 160
Phe Thr Leu Cys Gly Leu Asp Thr Ala Leu Tyr Asp Gly Thr Ala Ser
165 170 175
Asp Gly Glu Gln Ala Leu Tyr Met Ser Met Pro Cys Pro
180 185
2
570
DNA
Artificial Sequence
nrg1 - codons optimized for NRG (GC content
46.84%)
2
atgactactc ttgatgatac tgcttaccgt taccgtactt ctgttcctgg agatgctgag 60
gctatcgagg ctcttgatgg atctttcact actgatactg ttttccgtgt tactgctact 120
ggagatggat tcactcttcg tgaggttcct gttgatcctc ctcttactaa ggttttccct 180
gatgatgagt ctgatgatga gtctgatgat ggagaggatg gagatcctga ttctcgtact 240
ttcgttgctt acggagatga tggagatctt gctggattcg ttgttgtttc ttactctgga 300
tggaaccgtc gtcttactgt tgaggatatc gaggttgctc ctgagcatcg tggacatgga 360
gttggacgtg ctcttatggg acttgctact gagttcgctc gtgagcgtgg agctggacat 420
ctttggcttg aggttactaa cgttaacgct cctgctatcc atgcttaccg tcgtatggga 480
ttcactcttt gtggacttga tactgctctt tacgatggaa ctgcttctga tggagagcag 540
gctctttaca tgtctatgcc ttgtccttga 570
3
570
DNA
Artificial Sequence
nrg2 - codons not optimized for NRG (GC content
70.70%), after PCR reaction
3
atgaccactc ttgacgacac ggcttaccgg taccgcacca gtgtcccggg ggacgccgag 60
gccatcgagg cactggatgg gtccttcacc accgacaccg tcttccgcgt caccgccacc 120
ggggacggct tcaccctgcg ggaggtgccg gtggacccgc ccctgaccaa ggtgttcccc 180
gacgacgaat cggacgacga atcggacgac ggggaggacg gcgacccgga ctcccggacg 240
ttcgtcgcgt acggggacga cggcgacctg gcgggcttcg tggtcgtctc gtactccggc 300
tggaaccgcc ggctgaccgt cgaggacatc gaggtcgccc cggagcaccg ggggcacggg 360
gtcgggcgcg cgttgatggg gctcgcgacg gagttcgccc gcgagcgggg cgccgggcac 420
ctctggctgg aggtcaccaa cgtcaacgca ccggcgatcc acgcgtaccg gcggatgggg 480
ttcaccctct gcggcctgga caccgccctg tacgacggca ccgcctcgga cggcgagcag 540
gcgctctaca tgagcatgcc ctgcccctag 570
4
570
DNA
Artificial Sequence
nrg3 - codons optimized for NRG (GC content
46.84%)
4
atgactactc ttgatgatac tgcttaccgt taccgtactt ctgttcctgg agatgctgag 60
gctatcgagg ctcttgatgg atctttcact actgatactg ttttccgtgt tactgctact 120
ggagatggat tcactcttcg tgaggttcct gttgatcctc ctcttactaa ggttttccct 180
gatgatgagt ctgatgatga gtctgatgat ggagaggatg gagatcctga ttctcgtact 240
ttcgttgctt acggagatga tggagatctt gctggattcg ttgttgtttc ttactctgga 300
tggaaccgtc gtcttactgt tgaggatatc gaggttgctc ctgagcatcg tggacatgga 360
gttggacgtg ctcttatggg acttgctact gagttcgctc gtgagcgtgg agctggacat 420
ctttggcttg aggttactaa cgttaacgct cctgctatcc atgcttaccg tcgtatggga 480
ttcactcttt gtggacttga tactgctctt tacgatggaa ctgcttctga tggagagcag 540
gctctttaca tgtctatgcc ttgtccttga 570
5
30
DNA
Artificial Sequence
forward primer 5′nat1HindIII
5
ccgaagctta tgaccactct tgacgacacg 30
6
31
DNA
Artificial Sequence
reverse primer 3′nat1AvrII
6
aaccctaggc taggggcagg gcatgctcat g 31
7
4201
DNA
Artificial Sequence
plasmid pPG362 with nrg2 gene
7
gtgggggata aattcactgg ccgtcgtttt acaacgtcgt gactgggaaa accctggcgt 60
tacccaactt aatcgccttg cagcacatcc ccctttcgcc agctggcgta atagcgaaga 120
ggcccgcacc gatcgccctt cccaacagtt gcgcagcctg aatggcgaat ggcgcctgat 180
gcggtatttt ctccttacgc atctgtgcgg tatttcacac cgcatatggt gcactctcag 240
tacaatctgc tctgatgccg catagttaag ccagccccga cacccgccaa cacccgctga 300
cgcgccctga cgggcttgtc tgctcccggc atccgcttac agacaagctg tgaccgtctc 360
cgggagctgc atgtgtcaga ggttttcacc gtcatcaccg aaacgcgcga gacgaaaggg 420
cctcgtgata cgcctatttt tataggttaa tgtcatgata ataatggttt cttagacgtc 480
aggtggcact tttcggggaa atgtgcgcgg aacccctatt tgtttatttt tctaaataca 540
ttcaaatatg tatccgctca tgagacaata accctgataa atgcttcaat aatattgaaa 600
aaggaagagt atgagtattc aacatttccg tgtcgccctt attccctttt ttgcggcatt 660
ttgccttcct gtttttgctc acccagaaac gctggtgaaa gtaaaagatg ctgaagatca 720
gttgggtgca cgagtgggtt acatcgaact ggatctcaac agcggtaaga tccttgagag 780
ttttcgcccc gaagaacgtt ttccaatgat gagcactttt aaagttctgc tatgtggcgc 840
ggtattatcc cgtattgacg ccgggcaaga gcaactcggt cgccgcatac actattctca 900
gaatgacttg gttgagtact caccagtcac agaaaagcat cttacggatg gcatgacagt 960
aagagaatta tgcagtgctg ccataaccat gagtgataac actgcggcca acttacttct 1020
gacaacgatc ggaggaccga aggagctaac cgcttttttg cacaacatgg gggatcatgt 1080
aactcgcctt gatcgttggg aaccggagct gaatgaagcc ataccaaacg acgagcgtga 1140
caccacgatg cctgtagcaa tggcaacaac gttgcgcaaa ctattaactg gcgaactact 1200
tactctagct tcccggcaac aattaataga ctggatggag gcggataaag ttgcaggacc 1260
acttctgcgc tcggcccttc cggctggctg gtttattgct gataaatctg gagccggtga 1320
gcgtgggtct cgcggtatca ttgcagcact ggggccagat ggtaagccct cccgtatcgt 1380
agttatctac acgacgggga gtcaggcaac tatggatgaa cgaaatagac agatcgctga 1440
gataggtgcc tcactgatta agcattggta actgtcagac caagtttact catatatact 1500
ttagattgat ttaaaacttc atttttaatt taaaaggatc taggtgaaga tcctttttga 1560
taatctcatg accaaaatcc cttaacgtga gttttcgttc cactgagcgt cagaccccgt 1620
agaaaagatc aaaggatctt cttgagatcc tttttttctg cgcgtaatct gctgcttgca 1680
aacaaaaaaa ccaccgctac cagcggtggt ttgtttgccg gatcaagagc taccaactct 1740
ttttccgaag gtaactggct tcagcagagc gcagatacca aatactgtcc ttctagtgta 1800
gccgtagtta ggccaccact tcaagaactc tgtagcaccg cctacatacc tcgctctgct 1860
aatcctgtta ccagtggctg ctgccagtgg cgataagtcg tgtcttaccg ggttggactc 1920
aagacgatag ttaccggata aggcgcagcg gtcgggctga acggggggtt cgtgcacaca 1980
gcccagcttg gagcgaacga cctacaccga actgagatac ctacagcgtg agctatgaga 2040
aagcgccacg cttcccgaag ggagaaaggc ggacaggtat ccggtaagcg gcagggtcgg 2100
aacaggagag cgcacgaggg agcttccagg gggaaacgcc tggtatcttt atagtcctgt 2160
cgggtttcgc cacctctgac ttgagcgtcg atttttgtga tgctcgtcag gggggcggag 2220
cctatggaaa aacgccagca acgcggcctt tttacggttc ctggcctttt gctggccttt 2280
tgctcacatg ttctttcctg cgttatcccc tgattctgtg gataaccgta ttaccgcctt 2340
tgagtgagct gataccgctc gccgcagccg aacgaccgag cgcagcgagt cagtgagcga 2400
ggaagcggaa gagcgcccaa tacgcaaacc gcctctcccc gcgcgttggc cgattcatta 2460
atgcagctgg cacgacaggt ttcccgactg gaaagcgggc agtgagcgca acgcaattaa 2520
tgtgagttag ctcactcatt aggcacccca ggctttacac tttatgcttc cggctcgtat 2580
gttgtgtgga attgtgagcg gataacaatt tcacacagga aacagctatg accatgatta 2640
cgccaagcta taccccacgt gcgtacgctc gagtcacgct gccgcaagca ctcagggcgc 2700
aagggctgct aaaggaagcg gaacacgtag aaagccagtc cgcagaaacg gtgctgaccc 2760
cggatgaatg tcagctactg ggctatctgg acaagggaaa acgcaagcgc aaagagaaag 2820
caggtagctt gcagtgggct tacatggcga tagctagact gggcggtttt atggacagca 2880
agcgaaccgg aattgccagc tggggcgccc tctggtaagg ttgggaagcc ctgcaaagta 2940
aactggatgg ctttcttgcc gccaaggatc tgatggcgca ggggatcaag atcatgagcg 3000
gagaattaag ggagtcacgt tatgaccccc gccgatgacg cgggacaagc cgttttacgt 3060
ttggaactga cagaaccgca acgttgaagg agccactcag ccgcgggttt ctggagttta 3120
atgagctaag cacatacgtc agaaaccatt attgcgcgtt caaaagtcgc ctaaggtcac 3180
tatcagctag caaatatttc ttgtcaaaaa tgctccactg acgttccata aattcccctc 3240
ggtatccaat tagagtctca tattcactct caatccgtat accatggcta agcttatgac 3300
cactcttgac gacacggctt accggtaccg caccagtgtc ccgggggacg ccgaggccat 3360
cgaggcactg gatgggtcct tcaccaccga caccgtcttc cgcgtcaccg ccaccgggga 3420
cggcttcacc ctgcgggagg tgccggtgga cccgcccctg accaaggtgt tccccgacga 3480
cgaatcggac gacgaatcgg acgacgggga ggacggcgac ccggactccc ggacgttcgt 3540
cgcgtacggg gacgacggcg acctggcggg cttcgtggtc gtctcgtact ccggctggaa 3600
ccgccggctg accgtcgagg acatcgaggt cgccccggag caccgggggc acggggtcgg 3660
gcgcgcgttg atggggctcg cgacggagtt cgcccgcgag cggggcgccg ggcacctctg 3720
gctggaggtc accaacgtca acgcaccggc gatccacgcg taccggcgga tggggttcac 3780
cctctgcggc ctggacaccg ccctgtacga cggcaccgcc tcggacggcg agcaggcgct 3840
ctacatgagc atgccctgcc cctagcctag gcaactctcc tggcgcacca tcgtcggcta 3900
cagcctcggg aattgctacc gagctcgaat ttccccgatc gttcaaacat ttggcaataa 3960
agtttcttaa gattgaatcc tgttgccggt cttgcgatga ttatcatata atttctgttg 4020
aattacgtta agcatgtaat aattaacatg taatgcatga cgttatttat gagatgggtt 4080
tttatgatta gagtcccgca attatacatt taatacgcga tagaaaacaa aatatagcgc 4140
gcaaactagg ataaattatc gcgcgcggtg tcatctatgt tactagatcg ggaggcctca 4200
c 4201
8
11978
DNA
Artificial Sequence
plasmid pPG363 - binary vector with the nrg2
gene
8
tcccgcttcg ccggcgttaa ctcaagcgat tagatgcact aagcacataa ttgctcacag 60
ccaaactatc aggtcaagtc tgcttttatt atttttaagc gtgcataata agccctacac 120
aaattgggag atatatcatg catgaccaaa atcccttaac gtgagttttc gttccactga 180
gcgtcagacc ccgtagaaaa gatcaaagga tcttcttgag atcctttttt tctgcgcgta 240
atctgctgct tgcaaacaaa aaaaccaccg ctaccagcgg tggtttgttt gccggatcaa 300
gagctaccaa ctctttttcc gaaggtaact ggcttcagca gagcgcagat accaaatact 360
gtccttctag tgtagccgta gttaggccac cacttcaaga actctgtagc accgcctaca 420
tacctcgctc tgctaatcct gttaccagtg gctgctgcca gtggcgataa gtcgtgtctt 480
accgggttgg actcaagacg atagttaccg gataaggcgc agcggtcggg ctgaacgggg 540
ggttcgtgca cacagcccag cttggagcga acgacctaca ccgaactgag atacctacag 600
cgtgagctat gagaaagcgc cacgcttccc gaagggagaa aggcggacag gtatccggta 660
agcggcaggg tcggaacagg agagcgcacg agggagcttc cagggggaaa cgcctggtat 720
ctttatagtc ctgtcgggtt tcgccacctc tgacttgagc gtcgattttt gtgatgctcg 780
tcaggggggc ggagcctatg gaaaaacgcc agcaacgcgg cctttttacg gttcctggcc 840
ttttgctggc cttttgctca catgttcttt cctgcgttat cccctgattc tgtggataac 900
cgtattaccg cctttgagtg agctgatacc gctcgccgca gccgaacgac cgagcgcagc 960
gagtcagtga gcgaggaagc ggaagagcgc ctgatgcggt attttctcct tacgcatctg 1020
tgcggtattt cacaccgcat atggtgcact ctcagtacaa tctgctctga tgccgcatag 1080
ttaagccagt atacactccg ctatcgctac gtgactgggt catggctgcg ccccgacacc 1140
cgccaacacc cgctgacgcg ccctgacggg cttgtctgct cccggcatcc gcttacagac 1200
aagctgtgac cgtctccggg agctgcatgt gtcagaggtt ttcaccgtca tcaccgaaac 1260
gcgcgaggca gggtgccttg atgtgggcgc cggcggtcga gtggcgacgg cgcggcttgt 1320
ccgcgccctg gtagagcccg ggcgggtgtt ctgtcgtctc gttgtacaac gaaatccatt 1380
cccattccgc gctcaagatg gcttcccctc ggcagttcat cagggctaaa tcaatctagc 1440
cgacttgtcc ggtgaaatgg gctgcactcc aacagaaaca atcaaacaaa catacacagc 1500
gacttattca cacgagctca aattacaacg gtatatatcc tgccagtcag catcatcaca 1560
ccaaaagtta ggcccgaata gtttgaaatt agaaagctcg caattgaggt ctacaggcca 1620
aattcgctct tagccgtaca atattactca ccggtgcgat gccccccatc gtaggtgaag 1680
gtggaaatta atgatccatc ttgtctagag gcgcgccagg cctccatctt gaaagaaata 1740
tagtttaaat atttattgat aaaataagtc aggtattata gtccaagcaa aaacataatt 1800
tattgatgca aagtttaaat tcagaaatat ttcaataact gattatatca gctggtacat 1860
tgccgtagat gaaagactga gtgcgatatt atgtgtaata cataaattga tgatatagct 1920
agcttagctc atcgggccta ggtcattgtt tgcctccctg ctgcggtttt tcaccgaagt 1980
tcatgccagt ccagcgtttt tgcagcagaa aagccgccga cttcggtttg cggtcgcgag 2040
tgaagatccc tttcttgtta ccgccaacgc gcaatatgcc ttgcgaggtc gcaaaatcgg 2100
cgaaattcca tacctgttca ccgacgacgg cgctgacgcg atcaaagacg cggtgataca 2160
tatccagcca tgcacactga tactcttcac tccacatgtc ggtgtacatt gagtgcagcc 2220
cggctaacgt atccacgccg tattcggtga tgataatcgg ctgatgcagt ttctcctgcc 2280
aggccagaag ttctttttcc agtaccttct ctgccgtttc caaatcgccg ctttggacat 2340
accatccgta ataacggttc aggcacagca catcaaagag atcgctgatg gtatcggtgt 2400
gagcgtcgca gaacattaca ttgacgcagg tgatcggacg cgtcgggtcg agtttacgcg 2460
ttgcttccgc cagtggcgcg aaatattccc gtgcaccttg cggacgggta tccggttcgt 2520
tggcaatact ccacatcacc acgcttgggt ggtttttgtc acgcgctatc agctctttaa 2580
tcgcctgtaa gtgcgcttgc tgagtttccc cgttgactgc ctcttcgctg tacagttctt 2640
tcggcttgtt gcccgcttcg aaaccaatgc ctaaagagag gttaaagccg acagcagcag 2700
tttcatcaat caccacgatg ccatgttcat ctgcccagtc gagcatctct tcagcgtaag 2760
ggtaatgcga ggtacggtag gagttggccc caatccagtc cattaatgcg tggtcgtgca 2820
ccatcagcac gttatcgaat cctttgccac gcaagtccgc atcttcatga cgaccaaagc 2880
cagtaaagta gaacggtttg tggttaatca ggaactgttc gcccttcact gccactgacc 2940
ggatgccgac gcgaagcggg tagatatcac actctgtctg gcttttggct gtgacgcaca 3000
gttcatagag ataaccttca cccggttgcc agaggtgcgg attcaccact tgcaaagtcc 3060
cgctagtgcc ttgtccagtt gcaaccacct gttgatccgc atcacgcagt tcaacgctga 3120
catcaccatt ggccaccacc tgccagtcaa cagacgcgtg gttacagtct tgcgcgacat 3180
gcgtcaccac ggtgatatcg tccacccagg tgttcggcgt ggtgtagagc attacgctgc 3240
gatggattcc ggcatagtta aagaaatcat ggaagtaaga ctgctttttc ttgccgtttt 3300
cgtcggtaat caccattccc ggcgggatag tctgccagtt cagttcgttg ttcacacaaa 3360
cggtgatacg tacacttttc ccggcaataa catacggcgt gacatcggct tcaaatggcg 3420
tatagccgcc ctgatgctcc atcacttcct gattattgac ccacactttg ccgtaatgag 3480
tgaccgcatc gaaacgcagc acgatacgct ggcctgccca acctttcggt ataaagactt 3540
cgcgctgata ccagacgttg cccgcataat tacgaatatc tgcatcggcg aactgatcgt 3600
taaaactgcc tggcacagca attgcccggc tttcttgtaa cgcgctttcc caccaacgct 3660
gatcaattcc acagttttcg cgatccagac tgaatgccca caggccgtcg agttttttga 3720
tttcccgggt tggggtttct acctgaatta atttaccacg gttaatactc agatcaagat 3780
ggtaaaaaaa tggcggtaag attaatctgc acactgtaat taataatgta ccggacgtaa 3840
catatgaagc ttagccatgg gtgatttcag cgtgtcctct ccaaatgaaa tgaacttcct 3900
tatatagagg aagggtcttg cgaaggatag tgggattgtg cgtcatccct tacgtcagtg 3960
gagatatcac atcaatccac ttgctttgaa gacgtggttg gaacgtcttc tttttccacg 4020
atgctcctcg tgggtggggg tccatctttg ggaccactgt cggcagaggc atcttgaacg 4080
atagcctttc ctttatcgca atgatggcat ttgtagtgcc accttccttt tctactgtcc 4140
ttttgatgaa gtgacagata ggatcgggaa ttaattcgga tccgtacggc gcgccgcgcc 4200
atttaaatca cgtgaggcct cccgatctag taacatagat gacaccgcgc gcgataattt 4260
atcctagttt gcgcgctata ttttgttttc tatcgcgtat taaatgtata attgcgggac 4320
tctaatcata aaaacccatc tcataaataa cgtcatgcat tacatgttaa ttattacatg 4380
cttaacgtaa ttcaacagaa attatatgat aatcatcgca agaccggcaa caggattcaa 4440
tcttaagaaa ctttattgcc aaatgtttga acgatcgggg aaattcgagc tcggtagcaa 4500
ttcccgaggc tgtagccgac gatggtgcgc caggagagtt gcctaggcta ggggcagggc 4560
atgctcatgt agagcgcctg ctcgccgtcc gaggcggtgc cgtcgtacag ggcggtgtcc 4620
aggccgcaga gggtgaaccc catccgccgg tacgcgtgga tcgccggtgc gttgacgttg 4680
gtgacctcca gccagaggtg cccggcgccc cgctcgcggg cgaactccgt cgcgagcccc 4740
atcaacgcgc gcccgacccc gtgcccccgg tgctccgggg cgacctcgat gtcctcgacg 4800
gtcagccggc ggttccagcc ggagtacgag acgaccacga agcccgccag gtcgccgtcg 4860
tccccgtacg cgacgaacgt ccgggagtcc gggtcgccgt cctccccgtc gtccgattcg 4920
tcgtccgatt cgtcgtcggg gaacaccttg gtcaggggcg ggtccaccgg cacctcccgc 4980
agggtgaagc cgtccccggt ggcggtgacg cggaagacgg tgtcggtggt gaaggaccca 5040
tccagtgcct cgatggcctc ggcgtccccc gggacactgg tgcggtaccg gtaagccgtg 5100
tcgtcaagag tggtcataag cttagccatg gtatacggat tgagagtgaa tatgagactc 5160
taattggata ccgaggggaa tttatggaac gtcagtggag catttttgac aagaaatatt 5220
tgctagctga tagtgacctt aggcgacttt tgaacgcgca ataatggttt ctgacgtatg 5280
tgcttagctc attaaactcc agaaacccgc ggctgagtgg ctccttcaac gttgcggttc 5340
tgtcagttcc aaacgtaaaa cggcttgtcc cgcgtcatcg gcgggggtca taacgtgact 5400
cccttaattc tccgctcatg atcttgatcc cctgcgccat cagatccttg gcggcaagaa 5460
agccatccag tttactttgc agggcttccc aaccttacca gagggcgccc cagctggcaa 5520
ttccggttcg cttgctgtcc ataaaaccgc ccagtctagc tatcgccatg taagcccact 5580
gcaagctacc tgctttctct ttgcgcttgc gttttccctt gtccagatag cccagtagct 5640
gacattcatc cggggtcagc accgtttctg cggactggct ttctacgtgt tccgcttcct 5700
ttagcagccc ttgcgccctg agtgcttgcg gcagcgtgac tcgagcgtac gcacgtgggt 5760
cctattttat aataacgctg cggacatcta catttttgaa ttgaaaaaaa attggtaatt 5820
actctttctt tttctccata ttgaccatca tactcattgc tgatccatgt agatttcccg 5880
gacatgaagc catttacaat tgaatatatc ctgccgccgc tgccgctttg cacccggtgg 5940
agcttgcatg ttggtttcta cgcagaactg agccggttag gcagataatt tccattgaga 6000
actgagccat gtgcaccttc cccccaacac ggtgagcgac ggggcaacgg agtgatccac 6060
atgggacttt taaacatcat ccgtcggatg gcgttgcgag agaagcagtc gatccgtgag 6120
atcagccgac gcagcccggg ctgaggtctg cctcgtgaag aaggtgttgc tgactcatac 6180
caggcctgaa tcgccccatc atccagccag aaagtgaggg agccacggtt gatgagagct 6240
ttgttgtagg tggaccagtt ggtgattttg aacttttgct ttgccacgga acggtctgcg 6300
ttgtcgggaa gatgcgtgat ctgatccttc aactcagcaa aagttcgatt tattcaacaa 6360
agccgccgtc ccgtcaagtc agcgtaatgc tctgccagtg ttacaaccaa ttaaccaatt 6420
ctgattagaa aaactcatcg agcatcaaat gaaactgcaa tttattcata tcaggattat 6480
caataccata tttttgaaaa agccgtttct gtaatgaagg agaaaactca ccgaggcagt 6540
tccataggat ggcaagatcc tggtatcggt ctgcgattcc gactcgtcca acatcaatac 6600
aacctattaa tttcccctcg tcaaaaataa ggttatcaag tgagaaatca ccatgagtga 6660
cgactgaatc cggtgagaat ggcaacagct tatgcatttc tttccagact tgttcaacag 6720
gccagccatt acgctcgtca tcaaaatcac tcgcatcaac caaaccgtta ttcattcgtg 6780
attgcgcctg agcgagacga aatacgcgat cgctgttaaa aggacaatta caaacaggaa 6840
tcgaatgcaa ccggcgcagg aacactgcca gcgcatcaac aatattttca cctgaatcag 6900
gatattcttc taatacctgg aatgctgttt tcccggggat cgcagtggtg agtaaccatg 6960
catcatcagg agtacggata aaatgcttga tggtcggaag aggcataaat tccgtcagcc 7020
agtttagtct gaccatctca tctgtaacat cattggcaac gctacctttg ccatgtttca 7080
gaaacaactc tggcgcatcg ggcttcccat acaatcgata gattgtcgca cctgattgcc 7140
cgacattatc gcgagcccat ttatacccat ataaatcagc atccatgttg gaatttaatc 7200
gcggcctcga gcaagacgtt tcccgttgaa tatggctcat aacacccctt gtattactgt 7260
ttatgtaagc agacagtttt attgttcatg atgatatatt tttatcttgt gcaatgtaac 7320
atcagagatt ttgagacaca acgaagcttt ctgagccgcc gattttcctc ctcgagttgg 7380
atgaactcgc cgagttcatc gtcaactgaa acagacacgg ccggattctg tgagacaggt 7440
tgaaccgcag ctctcttcca ttgataatag gtctgaacgg aaatacccac gatcttaacg 7500
gcgtccttca aggttgcgcc gccagcgacc tgagcttcga tttgaccgat cttctccagt 7560
ttttctcggt tgctgaggcc gcgggttttc ggcttcacgg atttgaacga tcccgtgcgg 7620
gctgtttcgg ctggtgcttt ctttgctctt ctacctctag gagcagccgg ctcaacttcg 7680
gcagcagcag taccgtccgg cggattctgg atctcttcgt cagccattaa tcgtcctctg 7740
tgtgggttat tgctttgtct gccagctcga tccaagagtc aacgtttgtg cctagggcag 7800
taaataggca gtgctccgcg actacatgcc tcggccggca aaataccgcc gcatgtagag 7860
caggctctcc ttcacgatca acgatcggca tggggccttc gtgcttgttg agtaatgtta 7920
tcgctcccat cagagcacgc ttggtactcc gggaatcgga tggtctgtcg atcatccaaa 7980
aaacgctcat gttttcaacc tattaggtct gtggtcagct gaccacagac catcctgctc 8040
catactcgct aattctagcc aaaccgcaac gtcccctgcc cgctagcctt caagagcgcc 8100
attatcatcg ggccaagtga aaacttcccg agctcgctcc gccgtgtcag atctcggaga 8160
tagcccccgg gcgaattgat gaagttcgct cgctccaaaa tgcacgccat cgctgctgcc 8220
gcattctccg gtcccattgc ctcacacgcg tcttggtaag ccgacgggct gacccccagc 8280
atagaccgaa ccaccaccgc agccgacatg aggtcacgcc agctagcaac cgcaccgctc 8340
ggcccataat tgccaatggt cgggcatgct ttcaggatca tcccgagggg gaacgctttt 8400
atcggctcgc tccttgcccg gtctatttca ctcggcttag cgccctgctc cttttcagag 8460
cgaggttcaa gttcattaac ggattcgggt tttgaattct gtatgtgctg ctcgctctgg 8520
gcagcattgg tgctattatt ttctgaattg tctctaattt ccaaccggtt gattatctct 8580
tcctggagca tccacatctc ttcgagaatt gactctacat cagcaagcgt cggggcgcgt 8640
ggaattctac ccacaagttc cacatagact tcctcgacag cttgccagtc gccctccgct 8700
ccctcttcca tagctgccgt aattagcttc cgaacgtccc gtcggcaaat cgtcagactt 8760
tctttggcca tcctgaatgc tgctcgatcg gccatcacct gctgtgccat catcgctagc 8820
tcttcggacc gcgcgagaag cggagacaaa tcgaagccaa acgcgcgctc gatctgacca 8880
gcgccatcct tacgagcgta acgctttccg ttggcgctat ccttccggac gatcaagcct 8940
gactccacga gcatggcgat gtgcctacgc aaagtcgcgc cagccatccc atgcgcccga 9000
agggcaagct gagcattcga cgggaagacg atcagctgtg cctcctgacg caactccgtt 9060
tccgggtgaa agctcaatag cgcatcaagg acggcaagac tgttggactg gattccaagt 9120
agttccatgg ccgcggacgc gtctctaaag accttccact tgtccgctgt cttgccttgt 9180
ttgatatcgg ccagcgccgt ctggcgccgc acaagcgcaa gcgtcattgg ccgccgcccg 9240
aatggcgtcg ttacacttcc tgtctgcatc atctttcacc tttcagcagg caaaggaaat 9300
cagctcacca aaacggcgct aaaaactctt gacgaggatt cgaggaaatg cgattctgtt 9360
cgcgctagag agacagaagg gcttccgcga cggcgacgtt gagggggctc ttttcttttg 9420
cggtttactc tccccgtttc cgttggttct cagcgtggta cgcttgatac agcgctggca 9480
catgatcgag cacgaaggtc gcaaaatcgg gcgtcgcctt cctgtcaatc gtgatttcca 9540
gtttggcctt gctctgcgtc acctgtgcaa ttctggtgcc gtctggggtg gccatgacct 9600
cgggaagtcc acgcgcaacc cgactgggct tcagactagc gatcaccgcc ttgaatcgtt 9660
ctgccgatgg cagcgcttga acttcctccg acatagcata tttagccacg tcggccggtg 9720
aagaaacttt ctcaatcagc tcggcaagtt gttgccaact cggccgtcca acaccaggag 9780
cggcaccaat agcatcggtc agttcagagg ggagggcgtc gacgagcaga agcatcttgg 9840
acaaattgct cttgtcgatc gacatcgcgg cgatgacaat ctctcgagaa aactgcctgt 9900
tcaggcgatg tgcgaagcgc gccttttcga tgaaggtaag atcttcgcgc tcattgtttt 9960
cctgaccctg tgctacgacc acttgctcgt ccgtcagttc gcgaacgacc gctctgaccg 10020
gaagtccgag ttctgaaacg gcgcgtagcc ggcggtggcc gaaggcaacc tgatatcggc 10080
ccggctggct cggatgcggt cgcacaagga ttgggacttg ctgtccttgt tcccggatcg 10140
aagtaaggag cccgtcaatg tcccctcgca tacgatcctg cacgaaagac ggttctattg 10200
acgaggcatc caactctatc actgcctgac cttcagcgag acgccgctcg atctcttcgg 10260
cacggctaag acgatcgttt tgctctcgca gtgcgttacc aatgttcgct gtgagcttcg 10320
ttgccggatc gcgctccttc cttgttacgc cgaggagcgg catggagcgg ttctttgccg 10380
tcctattgtc ggcgggcgac gtctcagggg cgtcagttga gacgccaagg atgtgcttcc 10440
ggctcatgtg ggcctacccc atgctttttt gatcagtgtt tcgatctcgt cgttgacggc 10500
gttcatcgcc tccaaggctc gatcataggt cgagcgcgtg aacaggccac gctccacttc 10560
gaatagagtc tggtttgtca ggccagcgtc cgaaaccgcg gtggttttaa gcatcggaaa 10620
attgaggaca ttttcgccaa aaatcgaccg cagataacct accatttggt tctgtggtcc 10680
gtcgctcggt tcgaaacggg ttatcagata gcgcatccaa ttaaacttga acttggcgcc 10740
agcattctcg atttcacgca aaaggttcga tgtcattgcc agaaactggt tcatcgacat 10800
cacatccagc atctgcggat ggaccgtgac aagaatggac gtcgccgcag tcaatgcgga 10860
tagcgtgaga tacccaagct ggggagggca gtcgatgacc acgacgtcat agttatccgc 10920
gatatcttca attacttggc tgatgcgacc ataaaagagc gtgtcgccct ctttgcggtt 10980
catcagcgcg cgtggcgtat cgtgttcaaa ctccatcagc tcaaggttac caggaatcag 11040
gtggaggtcg ggaatgtaag tccctcggac gactcgttcg attgccacct gctcatcatc 11100
ataccttata gcgccgtaga gcgtttcgtt cgggccaacg tccgtctccg gttggctccc 11160
aaagagtgca gaaaggctcg cttgaggatc gagatcaatg gccaagactc gatatccgcg 11220
catagcgagg tactgcgcca gatgcgcggc ggtggtggtc ttacccgacc cacctttgaa 11280
attcatcaca gagataacct gaagctgctc gccgcctcga cgatgtggca ggtagcgccg 11340
gttcccgcgg ccgacctgat ccatatactt ccgaatcaca tggatatctt caattgagaa 11400
cattcgcctg ccacccgggc tcatgctaac attcaactct ggcatctcag acgcggtctg 11460
ccgtaaatat gactcgccaa cgccgagcag cttggacgcc tccgatggcc cgaatgttcg 11520
aatgcccttc tcggaatgcg gcgggaaaac cttaagatga tgtgcttgaa gttggctcga 11580
gagggcatcg gcatgacgct ccatcaaggc cgtcaaccct acaactacag gcgctgcttt 11640
taggacagac ttcgccatct caaacccatt ccttgccagt ggcgatattt ttcgcgaaac 11700
tggaaaagtt ccgccgctgg caattagcgc cgattctgct gtttgggcaa gagcttttag 11760
gttaacagaa ggttaacgcc ctcaggtcga aaaactccac ccaactgtta tttgtattta 11820
tttccaatgc cttagagaga ttgccatttg aatatgttca tgtattgttt tagtgataat 11880
cctacaatcg taacccaaaa agaggtcgcc ctctgcgcgc cgtcgtccaa tataggcgaa 11940
gtcacccttg cgactcaggc ggattctacc ttgtagga 11978
9
12438
DNA
Artificial Sequence
Plasmid pPG361
9
tcccgcttcg ccggcgttaa ctcaagcgat tagatgcact aagcacataa ttgctcacag 60
ccaaactatc aggtcaagtc tgcttttatt atttttaagc gtgcataata agccctacac 120
aaattgggag atatatcatg catgaccaaa atcccttaac gtgagttttc gttccactga 180
gcgtcagacc ccgtagaaaa gatcaaagga tcttcttgag atcctttttt tctgcgcgta 240
atctgctgct tgcaaacaaa aaaaccaccg ctaccagcgg tggtttgttt gccggatcaa 300
gagctaccaa ctctttttcc gaaggtaact ggcttcagca gagcgcagat accaaatact 360
gtccttctag tgtagccgta gttaggccac cacttcaaga actctgtagc accgcctaca 420
tacctcgctc tgctaatcct gttaccagtg gctgctgcca gtggcgataa gtcgtgtctt 480
accgggttgg actcaagacg atagttaccg gataaggcgc agcggtcggg ctgaacgggg 540
ggttcgtgca cacagcccag cttggagcga acgacctaca ccgaactgag atacctacag 600
cgtgagctat gagaaagcgc cacgcttccc gaagggagaa aggcggacag gtatccggta 660
agcggcaggg tcggaacagg agagcgcacg agggagcttc cagggggaaa cgcctggtat 720
ctttatagtc ctgtcgggtt tcgccacctc tgacttgagc gtcgattttt gtgatgctcg 780
tcaggggggc ggagcctatg gaaaaacgcc agcaacgcgg cctttttacg gttcctggcc 840
ttttgctggc cttttgctca catgttcttt cctgcgttat cccctgattc tgtggataac 900
cgtattaccg cctttgagtg agctgatacc gctcgccgca gccgaacgac cgagcgcagc 960
gagtcagtga gcgaggaagc ggaagagcgc ctgatgcggt attttctcct tacgcatctg 1020
tgcggtattt cacaccgcat atggtgcact ctcagtacaa tctgctctga tgccgcatag 1080
ttaagccagt atacactccg ctatcgctac gtgactgggt catggctgcg ccccgacacc 1140
cgccaacacc cgctgacgcg ccctgacggg cttgtctgct cccggcatcc gcttacagac 1200
aagctgtgac cgtctccggg agctgcatgt gtcagaggtt ttcaccgtca tcaccgaaac 1260
gcgcgaggca gggtgccttg atgtgggcgc cggcggtcga gtggcgacgg cgcggcttgt 1320
ccgcgccctg gtagagcccg ggcgggtgtt ctgtcgtctc gttgtacaac gaaatccatt 1380
cccattccgc gctcaagatg gcttcccctc ggcagttcat cagggctaaa tcaatctagc 1440
cgacttgtcc ggtgaaatgg gctgcactcc aacagaaaca atcaaacaaa catacacagc 1500
gacttattca cacgagctca aattacaacg gtatatatcc tgccagtcag catcatcaca 1560
ccaaaagtta ggcccgaata gtttgaaatt agaaagctcg caattgaggt ctacaggcca 1620
aattcgctct tagccgtaca atattactca ccggtgcgat gccccccatc gtaggtgaag 1680
gtggaaatta atgatccatc ttgtctagag gcgcgccagg cctccatctt gaaagaaata 1740
tagtttaaat atttattgat aaaataagtc aggtattata gtccaagcaa aaacataatt 1800
tattgatgca aagtttaaat tcagaaatat ttcaataact gattatatca gctggtacat 1860
tgccgtagat gaaagactga gtgcgatatt atgtgtaata cataaattga tgatatagct 1920
agcttagctc atcgggccta ggtcattgtt tgcctccctg ctgcggtttt tcaccgaagt 1980
tcatgccagt ccagcgtttt tgcagcagaa aagccgccga cttcggtttg cggtcgcgag 2040
tgaagatccc tttcttgtta ccgccaacgc gcaatatgcc ttgcgaggtc gcaaaatcgg 2100
cgaaattcca tacctgttca ccgacgacgg cgctgacgcg atcaaagacg cggtgataca 2160
tatccagcca tgcacactga tactcttcac tccacatgtc ggtgtacatt gagtgcagcc 2220
cggctaacgt atccacgccg tattcggtga tgataatcgg ctgatgcagt ttctcctgcc 2280
aggccagaag ttctttttcc agtaccttct ctgccgtttc caaatcgccg ctttggacat 2340
accatccgta ataacggttc aggcacagca catcaaagag atcgctgatg gtatcggtgt 2400
gagcgtcgca gaacattaca ttgacgcagg tgatcggacg cgtcgggtcg agtttacgcg 2460
ttgcttccgc cagtggcgcg aaatattccc gtgcaccttg cggacgggta tccggttcgt 2520
tggcaatact ccacatcacc acgcttgggt ggtttttgtc acgcgctatc agctctttaa 2580
tcgcctgtaa gtgcgcttgc tgagtttccc cgttgactgc ctcttcgctg tacagttctt 2640
tcggcttgtt gcccgcttcg aaaccaatgc ctaaagagag gttaaagccg acagcagcag 2700
tttcatcaat caccacgatg ccatgttcat ctgcccagtc gagcatctct tcagcgtaag 2760
ggtaatgcga ggtacggtag gagttggccc caatccagtc cattaatgcg tggtcgtgca 2820
ccatcagcac gttatcgaat cctttgccac gcaagtccgc atcttcatga cgaccaaagc 2880
cagtaaagta gaacggtttg tggttaatca ggaactgttc gcccttcact gccactgacc 2940
ggatgccgac gcgaagcggg tagatatcac actctgtctg gcttttggct gtgacgcaca 3000
gttcatagag ataaccttca cccggttgcc agaggtgcgg attcaccact tgcaaagtcc 3060
cgctagtgcc ttgtccagtt gcaaccacct gttgatccgc atcacgcagt tcaacgctga 3120
catcaccatt ggccaccacc tgccagtcaa cagacgcgtg gttacagtct tgcgcgacat 3180
gcgtcaccac ggtgatatcg tccacccagg tgttcggcgt ggtgtagagc attacgctgc 3240
gatggattcc ggcatagtta aagaaatcat ggaagtaaga ctgctttttc ttgccgtttt 3300
cgtcggtaat caccattccc ggcgggatag tctgccagtt cagttcgttg ttcacacaaa 3360
cggtgatacg tacacttttc ccggcaataa catacggcgt gacatcggct tcaaatggcg 3420
tatagccgcc ctgatgctcc atcacttcct gattattgac ccacactttg ccgtaatgag 3480
tgaccgcatc gaaacgcagc acgatacgct ggcctgccca acctttcggt ataaagactt 3540
cgcgctgata ccagacgttg cccgcataat tacgaatatc tgcatcggcg aactgatcgt 3600
taaaactgcc tggcacagca attgcccggc tttcttgtaa cgcgctttcc caccaacgct 3660
gatcaattcc acagttttcg cgatccagac tgaatgccca caggccgtcg agttttttga 3720
tttcccgggt tggggtttct acctgaatta atttaccacg gttaatactc agatcaagat 3780
ggtaaaaaaa tggcggtaag attaatctgc acactgtaat taataatgta ccggacgtaa 3840
catatgaagc ttagccatgg gtgatttcag cgtgtcctct ccaaatgaaa tgaacttcct 3900
tatatagagg aagggtcttg cgaaggatag tgggattgtg cgtcatccct tacgtcagtg 3960
gagatatcac atcaatccac ttgctttgaa gacgtggttg gaacgtcttc tttttccacg 4020
atgctcctcg tgggtggggg tccatctttg ggaccactgt cggcagaggc atcttgaacg 4080
atagcctttc ctttatcgca atgatggcat ttgtagtgcc accttccttt tctactgtcc 4140
ttttgatgaa gtgacagata ggatcgggaa ttaattcgga tccgtacggc gcgccgcgcc 4200
atttaaatca cgtgcgtacg ctcgagtcac gctgccgcaa gcactcaggg cgcaagggct 4260
gctaaaggaa gcggaacacg tagaaagcca gtccgcagaa acggtgctga ccccggatga 4320
atgtcagcta ctgggctatc tggacaaggg aaaacgcaag cgcaaagaga aagcaggtag 4380
cttgcagtgg gcttacatgg cgatagctag actgggcggt tttatggaca gcaagcgaac 4440
cggaattgcc agctggggcg ccctctggta aggttgggaa gccctgcaaa gtaaactgga 4500
tggctttctt gccgccaagg atctgatggc gcaggggatc aagatcatga gcggagaatt 4560
aagggagtca cgttatgacc cccgccgatg acgcgggaca agccgtttta cgtttggaac 4620
tgacagaacc gcaacgttga aggagccact cagccgcggg tttctggagt ttaatgagct 4680
aagcacatac gtcagaaacc attattgcgc gttcaaaagt cgcctaaggt cactatcagc 4740
tagcaaatat ttcttgtcaa aaatgctcca ctgacgttcc ataaattccc ctcggtatcc 4800
aattagagtc tcatattcac tctcaatccg tataccatgg ctaagcttat gaaaaagcct 4860
gaactcaccg cgacgtctgt cgagaagttt ctgatcgaaa agttcgacag cgtctccgac 4920
ctgatgcagc tctcggaggg cgaagaatct cgtgctttca gcttcgatgt aggagggcgt 4980
ggatatgtcc tgcgggtaaa tagctgcgcc gatggtttct acaaagatcg ttatgtttat 5040
cggcactttg catcggccgc gctcccgatt ccggaagtgc ttgacattgg ggcattcagc 5100
gagagcctga cctattgcat ctcccgccgt gcacagggtg tcacgttgca agacctgcct 5160
gaaaccgaac tgcccgctgt tctgcagccg gtcgcggagg ccatggatgc gatcgctgcg 5220
gccgatctta gccagacgag cgggttcggc ccattcggac cgcaaggaat cggtcaatac 5280
actacatggc gtgatttcat atgcgcgatt gctgatcccc atgtgtatca ctggcaaact 5340
gtgatggacg acaccgtcag tgcgtccgtc gcgcaggctc tcgatgagct gatgctttgg 5400
gccgaggact gccccgaagt ccggcacctc gtgcacgcgg atttcggctc caacaatgtc 5460
ctgacggaca atggccgcat aacagcggtc attgactgga gcgaggcgat gttcggggat 5520
tcccaatacg aggtcgccaa catcttcttc tggaggccgt ggttggcttg tatggagcag 5580
cagacgcgct acttcgagcg gaggcatccg gagcttgcag gatcgccgcg gctccgggcg 5640
tatatgctcc gcattggtct tgaccaactc tatcagagct tggttgacgg caatttcgat 5700
gatgcagctt gggcgcaggg tcgatgcgac gcaatcgtcc gatccggagc cgggactgtc 5760
gggcgtacac aaatcgcccg cagaagcgcg gccgtctgga ccgatggctg tgtagaagta 5820
ctcgccgata gtggaaaccg acgccccagc actcgtccga gggcaaagga atagaattcc 5880
taggcaactc tcctggcgca ccatcgtcgg ctacagcctc gggaattgct accgagctcg 5940
aatttccccg atcgttcaaa catttggcaa taaagtttct taagattgaa tcctgttgcc 6000
ggtcttgcga tgattatcat ataatttctg ttgaattacg ttaagcatgt aataattaac 6060
atgtaatgca tgacgttatt tatgagatgg gtttttatga ttagagtccc gcaattatac 6120
atttaatacg cgatagaaaa caaaatatag cgcgcaaact aggataaatt atcgcgcgcg 6180
gtgtcatcta tgttactaga tcgggaggcc tcacgtgggt cctattttat aataacgctg 6240
cggacatcta catttttgaa ttgaaaaaaa attggtaatt actctttctt tttctccata 6300
ttgaccatca tactcattgc tgatccatgt agatttcccg gacatgaagc catttacaat 6360
tgaatatatc ctgccgccgc tgccgctttg cacccggtgg agcttgcatg ttggtttcta 6420
cgcagaactg agccggttag gcagataatt tccattgaga actgagccat gtgcaccttc 6480
cccccaacac ggtgagcgac ggggcaacgg agtgatccac atgggacttt taaacatcat 6540
ccgtcggatg gcgttgcgag agaagcagtc gatccgtgag atcagccgac gcagcccggg 6600
ctgaggtctg cctcgtgaag aaggtgttgc tgactcatac caggcctgaa tcgccccatc 6660
atccagccag aaagtgaggg agccacggtt gatgagagct ttgttgtagg tggaccagtt 6720
ggtgattttg aacttttgct ttgccacgga acggtctgcg ttgtcgggaa gatgcgtgat 6780
ctgatccttc aactcagcaa aagttcgatt tattcaacaa agccgccgtc ccgtcaagtc 6840
agcgtaatgc tctgccagtg ttacaaccaa ttaaccaatt ctgattagaa aaactcatcg 6900
agcatcaaat gaaactgcaa tttattcata tcaggattat caataccata tttttgaaaa 6960
agccgtttct gtaatgaagg agaaaactca ccgaggcagt tccataggat ggcaagatcc 7020
tggtatcggt ctgcgattcc gactcgtcca acatcaatac aacctattaa tttcccctcg 7080
tcaaaaataa ggttatcaag tgagaaatca ccatgagtga cgactgaatc cggtgagaat 7140
ggcaacagct tatgcatttc tttccagact tgttcaacag gccagccatt acgctcgtca 7200
tcaaaatcac tcgcatcaac caaaccgtta ttcattcgtg attgcgcctg agcgagacga 7260
aatacgcgat cgctgttaaa aggacaatta caaacaggaa tcgaatgcaa ccggcgcagg 7320
aacactgcca gcgcatcaac aatattttca cctgaatcag gatattcttc taatacctgg 7380
aatgctgttt tcccggggat cgcagtggtg agtaaccatg catcatcagg agtacggata 7440
aaatgcttga tggtcggaag aggcataaat tccgtcagcc agtttagtct gaccatctca 7500
tctgtaacat cattggcaac gctacctttg ccatgtttca gaaacaactc tggcgcatcg 7560
ggcttcccat acaatcgata gattgtcgca cctgattgcc cgacattatc gcgagcccat 7620
ttatacccat ataaatcagc atccatgttg gaatttaatc gcggcctcga gcaagacgtt 7680
tcccgttgaa tatggctcat aacacccctt gtattactgt ttatgtaagc agacagtttt 7740
attgttcatg atgatatatt tttatcttgt gcaatgtaac atcagagatt ttgagacaca 7800
acgaagcttt ctgagccgcc gattttcctc ctcgagttgg atgaactcgc cgagttcatc 7860
gtcaactgaa acagacacgg ccggattctg tgagacaggt tgaaccgcag ctctcttcca 7920
ttgataatag gtctgaacgg aaatacccac gatcttaacg gcgtccttca aggttgcgcc 7980
gccagcgacc tgagcttcga tttgaccgat cttctccagt ttttctcggt tgctgaggcc 8040
gcgggttttc ggcttcacgg atttgaacga tcccgtgcgg gctgtttcgg ctggtgcttt 8100
ctttgctctt ctacctctag gagcagccgg ctcaacttcg gcagcagcag taccgtccgg 8160
cggattctgg atctcttcgt cagccattaa tcgtcctctg tgtgggttat tgctttgtct 8220
gccagctcga tccaagagtc aacgtttgtg cctagggcag taaataggca gtgctccgcg 8280
actacatgcc tcggccggca aaataccgcc gcatgtagag caggctctcc ttcacgatca 8340
acgatcggca tggggccttc gtgcttgttg agtaatgtta tcgctcccat cagagcacgc 8400
ttggtactcc gggaatcgga tggtctgtcg atcatccaaa aaacgctcat gttttcaacc 8460
tattaggtct gtggtcagct gaccacagac catcctgctc catactcgct aattctagcc 8520
aaaccgcaac gtcccctgcc cgctagcctt caagagcgcc attatcatcg ggccaagtga 8580
aaacttcccg agctcgctcc gccgtgtcag atctcggaga tagcccccgg gcgaattgat 8640
gaagttcgct cgctccaaaa tgcacgccat cgctgctgcc gcattctccg gtcccattgc 8700
ctcacacgcg tcttggtaag ccgacgggct gacccccagc atagaccgaa ccaccaccgc 8760
agccgacatg aggtcacgcc agctagcaac cgcaccgctc ggcccataat tgccaatggt 8820
cgggcatgct ttcaggatca tcccgagggg gaacgctttt atcggctcgc tccttgcccg 8880
gtctatttca ctcggcttag cgccctgctc cttttcagag cgaggttcaa gttcattaac 8940
ggattcgggt tttgaattct gtatgtgctg ctcgctctgg gcagcattgg tgctattatt 9000
ttctgaattg tctctaattt ccaaccggtt gattatctct tcctggagca tccacatctc 9060
ttcgagaatt gactctacat cagcaagcgt cggggcgcgt ggaattctac ccacaagttc 9120
cacatagact tcctcgacag cttgccagtc gccctccgct ccctcttcca tagctgccgt 9180
aattagcttc cgaacgtccc gtcggcaaat cgtcagactt tctttggcca tcctgaatgc 9240
tgctcgatcg gccatcacct gctgtgccat catcgctagc tcttcggacc gcgcgagaag 9300
cggagacaaa tcgaagccaa acgcgcgctc gatctgacca gcgccatcct tacgagcgta 9360
acgctttccg ttggcgctat ccttccggac gatcaagcct gactccacga gcatggcgat 9420
gtgcctacgc aaagtcgcgc cagccatccc atgcgcccga agggcaagct gagcattcga 9480
cgggaagacg atcagctgtg cctcctgacg caactccgtt tccgggtgaa agctcaatag 9540
cgcatcaagg acggcaagac tgttggactg gattccaagt agttccatgg ccgcggacgc 9600
gtctctaaag accttccact tgtccgctgt cttgccttgt ttgatatcgg ccagcgccgt 9660
ctggcgccgc acaagcgcaa gcgtcattgg ccgccgcccg aatggcgtcg ttacacttcc 9720
tgtctgcatc atctttcacc tttcagcagg caaaggaaat cagctcacca aaacggcgct 9780
aaaaactctt gacgaggatt cgaggaaatg cgattctgtt cgcgctagag agacagaagg 9840
gcttccgcga cggcgacgtt gagggggctc ttttcttttg cggtttactc tccccgtttc 9900
cgttggttct cagcgtggta cgcttgatac agcgctggca catgatcgag cacgaaggtc 9960
gcaaaatcgg gcgtcgcctt cctgtcaatc gtgatttcca gtttggcctt gctctgcgtc 10020
acctgtgcaa ttctggtgcc gtctggggtg gccatgacct cgggaagtcc acgcgcaacc 10080
cgactgggct tcagactagc gatcaccgcc ttgaatcgtt ctgccgatgg cagcgcttga 10140
acttcctccg acatagcata tttagccacg tcggccggtg aagaaacttt ctcaatcagc 10200
tcggcaagtt gttgccaact cggccgtcca acaccaggag cggcaccaat agcatcggtc 10260
agttcagagg ggagggcgtc gacgagcaga agcatcttgg acaaattgct cttgtcgatc 10320
gacatcgcgg cgatgacaat ctctcgagaa aactgcctgt tcaggcgatg tgcgaagcgc 10380
gccttttcga tgaaggtaag atcttcgcgc tcattgtttt cctgaccctg tgctacgacc 10440
acttgctcgt ccgtcagttc gcgaacgacc gctctgaccg gaagtccgag ttctgaaacg 10500
gcgcgtagcc ggcggtggcc gaaggcaacc tgatatcggc ccggctggct cggatgcggt 10560
cgcacaagga ttgggacttg ctgtccttgt tcccggatcg aagtaaggag cccgtcaatg 10620
tcccctcgca tacgatcctg cacgaaagac ggttctattg acgaggcatc caactctatc 10680
actgcctgac cttcagcgag acgccgctcg atctcttcgg cacggctaag acgatcgttt 10740
tgctctcgca gtgcgttacc aatgttcgct gtgagcttcg ttgccggatc gcgctccttc 10800
cttgttacgc cgaggagcgg catggagcgg ttctttgccg tcctattgtc ggcgggcgac 10860
gtctcagggg cgtcagttga gacgccaagg atgtgcttcc ggctcatgtg ggcctacccc 10920
atgctttttt gatcagtgtt tcgatctcgt cgttgacggc gttcatcgcc tccaaggctc 10980
gatcataggt cgagcgcgtg aacaggccac gctccacttc gaatagagtc tggtttgtca 11040
ggccagcgtc cgaaaccgcg gtggttttaa gcatcggaaa attgaggaca ttttcgccaa 11100
aaatcgaccg cagataacct accatttggt tctgtggtcc gtcgctcggt tcgaaacggg 11160
ttatcagata gcgcatccaa ttaaacttga acttggcgcc agcattctcg atttcacgca 11220
aaaggttcga tgtcattgcc agaaactggt tcatcgacat cacatccagc atctgcggat 11280
ggaccgtgac aagaatggac gtcgccgcag tcaatgcgga tagcgtgaga tacccaagct 11340
ggggagggca gtcgatgacc acgacgtcat agttatccgc gatatcttca attacttggc 11400
tgatgcgacc ataaaagagc gtgtcgccct ctttgcggtt catcagcgcg cgtggcgtat 11460
cgtgttcaaa ctccatcagc tcaaggttac caggaatcag gtggaggtcg ggaatgtaag 11520
tccctcggac gactcgttcg attgccacct gctcatcatc ataccttata gcgccgtaga 11580
gcgtttcgtt cgggccaacg tccgtctccg gttggctccc aaagagtgca gaaaggctcg 11640
cttgaggatc gagatcaatg gccaagactc gatatccgcg catagcgagg tactgcgcca 11700
gatgcgcggc ggtggtggtc ttacccgacc cacctttgaa attcatcaca gagataacct 11760
gaagctgctc gccgcctcga cgatgtggca ggtagcgccg gttcccgcgg ccgacctgat 11820
ccatatactt ccgaatcaca tggatatctt caattgagaa cattcgcctg ccacccgggc 11880
tcatgctaac attcaactct ggcatctcag acgcggtctg ccgtaaatat gactcgccaa 11940
cgccgagcag cttggacgcc tccgatggcc cgaatgttcg aatgcccttc tcggaatgcg 12000
gcgggaaaac cttaagatga tgtgcttgaa gttggctcga gagggcatcg gcatgacgct 12060
ccatcaaggc cgtcaaccct acaactacag gcgctgcttt taggacagac ttcgccatct 12120
caaacccatt ccttgccagt ggcgatattt ttcgcgaaac tggaaaagtt ccgccgctgg 12180
caattagcgc cgattctgct gtttgggcaa gagcttttag gttaacagaa ggttaacgcc 12240
ctcaggtcga aaaactccac ccaactgtta tttgtattta tttccaatgc cttagagaga 12300
ttgccatttg aatatgttca tgtattgttt tagtgataat cctacaatcg taacccaaaa 12360
agaggtcgcc ctctgcgcgc cgtcgtccaa tataggcgaa gtcacccttg cgactcaggc 12420
ggattctacc ttgtagga 12438
10
4297
DNA
Artificial Sequence
Plasmid pPG354
10
tcgcgcgttt cggtgatgac ggtgaaaacc tctgacacat gcagctcccg gagacggtca 60
cagcttgtct gtaagcggat gccgggagca gacaagcccg tcagggcgcg tcagcgggtg 120
ttggcgggtg tcggggctgg cttaactatg cggcatcaga gcagattgta ctgagagtgc 180
accatatgcg gtgtgaaata ccgcacagat gcgtaaggag aaaataccgc atcaggcgcc 240
attcgccatt caggctgcgc aactgttggg aagggcgatc ggtgcgggcc tcttcgctat 300
tacgccagct ggcgaaaggg ggatgtgctg caaggcgatt aagttgggta acgccagggt 360
tttcccagtc acgacgttgt aaaacgacgg ccagtgaatt tatcccccac gtgcgtacga 420
tcatgagcgg agaattaagg gagtcacgtt atgacccccg ccgatgacgc gggacaagcc 480
gttttacgtt tggaactgac agaaccgcaa cgttgaagga gccactcagc cgcgggtttc 540
tggagtttaa tgagctaagc acatacgtca gaaaccatta ttgcgcgttc aaaagtcgcc 600
taaggtcact atcagctagc aaatatttct tgtcaaaaat gctccactga cgttccataa 660
attcccctcg gtatccaatt agagtctcat attcactctc aatccaaata atctgcagat 720
cctagacgat cgtttcgcca tggctaagct tatgaaaaag cctgaactca ccgcgacgtc 780
tgtcgagaag tttctgatcg aaaagttcga cagcgtctcc gacctgatgc agctctcgga 840
gggcgaagaa tctcgtgctt tcagcttcga tgtaggaggg cgtggatatg tcctgcgggt 900
aaatagctgc gccgatggtt tctacaaaga tcgttatgtt tatcggcact ttgcatcggc 960
cgcgctcccg attccggaag tgcttgacat tggggaattc agcgagagcc tgacctattg 1020
catctcccgc cgtgcacagg gtgtcacgtt gcaagacctg cctgaaaccg aactgcccgc 1080
tgttctgcag ccggtcgcgg aggccatgga tgcgatcgct gcggccgatc ttagccagac 1140
gagcgggttc ggcccattcg gaccgcaagg aatcggtcaa tacactacat ggcgtgattt 1200
catatgcgcg attgctgatc cccatgtgta tcactggcaa actgtgatgg acgacaccgt 1260
cagtgcgtcc gtcgcgcagg ctctcgatga gctgatgctt tgggccgagg actgccccga 1320
agtccggcac ctcgtgcacg cggatttcgg ctccaacaat gtcctgacgg acaatggccg 1380
cataacagcg gtcattgact ggagcgaggc gatgttcggg gattcccaat acgaggtcgc 1440
caacatcttc ttctggaggc cgtggttggc ttgtatggag cagcagacgc gctacttcga 1500
gcggaggcat ccggagcttg caggatcgcc gcggctccgg gcgtatatgc tccgcattgg 1560
tcttgaccaa ctctatcaga gcttggttga cggcaatttc gatgatgcag cttgggcgca 1620
gggtcgatgc gacgcaatcg tccgatccgg agccgggact gtcgggcgta cacaaatcgc 1680
ccgcagaagc gcggccgtct ggaccgatgg ctgtgtagaa gtactcgccg atagtggaaa 1740
ccgacgcccc agcactcgtc cgagggcaaa ggaatagaat tcctaggatc gttcaaacat 1800
ttggcaataa agtttcttaa gattgaatcc tgttgccggt cttgcgatga ttatcatata 1860
atttctgttg aattacgtta agcatgtaat aattaacatg taatgcatga cgttatttat 1920
gagatgggtt tttatgatta gagtcccgca attatacatt taatacgcga tagaaaacaa 1980
aatatagcgc gcaaactagg ataaattatc gcgcgcggtg tcatctatgt tactagatcg 2040
aggcctcacg tggggtatag cttggcgtaa tcatggtcat agctgtttcc tgtgtgaaat 2100
tgttatccgc tcacaattcc acacaacata cgagccggaa gcataaagtg taaagcctgg 2160
ggtgcctaat gagtgagcta actcacatta attgcgttgc gctcactgcc cgctttccag 2220
tcgggaaacc tgtcgtgcca gctgcattaa tgaatcggcc aacgcgcggg gagaggcggt 2280
ttgcgtattg ggcgctcttc cgcttcctcg ctcactgact cgctgcgctc ggtcgttcgg 2340
ctgcggcgag cggtatcagc tcactcaaag gcggtaatac ggttatccac agaatcaggg 2400
gataacgcag gaaagaacat gtgagcaaaa ggccagcaaa aggccaggaa ccgtaaaaag 2460
gccgcgttgc tggcgttttt ccataggctc cgcccccctg acgagcatca caaaaatcga 2520
cgctcaagtc agaggtggcg aaacccgaca ggactataaa gataccaggc gtttccccct 2580
ggaagctccc tcgtgcgctc tcctgttccg accctgccgc ttaccggata cctgtccgcc 2640
tttctccctt cgggaagcgt ggcgctttct catagctcac gctgtaggta tctcagttcg 2700
gtgtaggtcg ttcgctccaa gctgggctgt gtgcacgaac cccccgttca gcccgaccgc 2760
tgcgccttat ccggtaacta tcgtcttgag tccaacccgg taagacacga cttatcgcca 2820
ctggcagcag ccactggtaa caggattagc agagcgaggt atgtaggcgg tgctacagag 2880
ttcttgaagt ggtggcctaa ctacggctac actagaagga cagtatttgg tatctgcgct 2940
ctgctgaagc cagttacctt cggaaaaaga gttggtagct cttgatccgg caaacaaacc 3000
accgctggta gcggtggttt ttttgtttgc aagcagcaga ttacgcgcag aaaaaaagga 3060
tctcaagaag atcctttgat cttttctacg gggtctgacg ctcagtggaa cgaaaactca 3120
cgttaaggga ttttggtcat gagattatca aaaaggatct tcacctagat ccttttaaat 3180
taaaaatgaa gttttaaatc aatctaaagt atatatgagt aaacttggtc tgacagttac 3240
caatgcttaa tcagtgaggc acctatctca gcgatctgtc tatttcgttc atccatagtt 3300
gcctgactcc ccgtcgtgta gataactacg atacgggagg gcttaccatc tggccccagt 3360
gctgcaatga taccgcgaga cccacgctca ccggctccag atttatcagc aataaaccag 3420
ccagccggaa gggccgagcg cagaagtggt cctgcaactt tatccgcctc catccagtct 3480
attaattgtt gccgggaagc tagagtaagt agttcgccag ttaatagttt gcgcaacgtt 3540
gttgccattg ctacaggcat cgtggtgtca cgctcgtcgt ttggtatggc ttcattcagc 3600
tccggttccc aacgatcaag gcgagttaca tgatccccca tgttgtgcaa aaaagcggtt 3660
agctccttcg gtcctccgat cgttgtcaga agtaagttgg ccgcagtgtt atcactcatg 3720
gttatggcag cactgcataa ttctcttact gtcatgccat ccgtaagatg cttttctgtg 3780
actggtgagt actcaaccaa gtcattctga gaatagtgta tgcggcgacc gagttgctct 3840
tgcccggcgt caatacggga taataccgcg ccacatagca gaactttaaa agtgctcatc 3900
attggaaaac gttcttcggg gcgaaaactc tcaaggatct taccgctgtt gagatccagt 3960
tcgatgtaac ccactcgtgc acccaactga tcttcagcat cttttacttt caccagcgtt 4020
tctgggtgag caaaaacagg aaggcaaaat gccgcaaaaa agggaataag ggcgacacgg 4080
aaatgttgaa tactcatact cttccttttt caatattatt gaagcattta tcagggttat 4140
tgtctcatga gcggatacat atttgaatgt atttagaaaa ataaacaaat aggggttccg 4200
cgcacatttc cccgaaaagt gccacctgac gtctaagaaa ccattattat catgacatta 4260
acctataaaa ataggcgtat cacgaggccc tttcgtc 4297
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Novel protein useful as a selectable marker resistant to the antibiotic nourseothricin and corresponding polynucleotides for insertion of genes and other genetic material into a variety of organisms, including plants are described.
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FIELD OF THE INVENTION
This invention relates to hot water vacuum extraction machines and, more particularly, to a dual inlet muffler assembly for a truck mounted hot water vacuum extraction machine which requires multiple vacuum pumps for pulling down the vacuum in the closed, dirty water dump tank necessary to such apparatus.
BACKGROUND OF THE INVENTION
Applicant's corporate assignee has developed a line of hot water vacuum extraction machines for cleaning wall to wall rugs, carpets and the like. Such machines are disclosed in the corporate assignee's U.S. patents including:
U.S. Pat. No. 3,896,521 issued July 29, 1975;
U.S. Pat. No. 3,911,524 issued October 14, 1975;
U.S. Pat. No. 4,088,462 issued May 9, 1978.
These machines are characterized by two side by side tanks mounted on a mobile chassis, one of the tanks bearing a supply of hot water with a soap or chemical cleaner forming a cleaning solution. The other tank is connected to a source of vacuum pressure and functions as a dirty water return or vacuum dump tank whose contents may be dumped or otherwise removed from time to time. Conventionally the machine's system employ a tubular metal or plastic wand which terminates in a vacuum pick up head at one end and whose opposite end is hose connected to the vacuum dump tank such that when the interior of the vacuum dump tank is subjected to vacuum pressure, a suction force extends through the hose, the wand and the vacuum pick up head to suck up the cleaning solution sprayed onto the rug and thus the dirt entrained in the cleaning solution, all of which is returned to the vacuum dump tank.
For a much larger hot water vacuum extraction machine mounted to a truck chasis, the vacuum dump tank is considerably larger and requires more than one vacuum pump to pull down the tank interior to the desired vacuum pressure. Such vacuum pumps create significant noise during their operation and require the noise carried by the positive air pressure exhaust to be muffled prior to discharge to the atmosphere.
It is, therefore, a primary object of the present invention to provide an improved muffler assembly which effectively muffles the exhaust from dual vacuum pumps by means of a single unit coupled to both vacuum pump positive pressure air exhaust flows.
It is a further object of the present invention to provide such an improved muffler assembly wherein the components of the assembly can withstand the effects of moisture carried in the exhaust flows from the vacuum pumps.
SUMMARY OF THE INVENTION
The present invention is directed to a dual inlet muffler assembly for a truck mounted hot water vacuum extraction machine where the machine is of the type using a closed dirty water return on vacuum dump tank which is hose connected to a vacuum pick up wand functioning to return cleaning liquid and entrained dirt from a surface being cleaned to the dump tank under vacuum pressure applied internally to the dump tank. The dump tank includes a riser tube within the tank which extends upwardly from the tank bottom and which opens to the tank interior at one end and to the tank exterior at the tank bottom wall. A first motor driven vacuum pump is connected to the dump tank riser tube and a second motor driven vacuum pump is connected in parallel, to the same riser tube. Each vacuum pump includes a positive air pressure exhaust pipe leading therefrom. The muffler assembly comprises a hollow plastic muffler body, a first plastic pipe extending completely through the hollow body and bearing perforations within a portion of the pipe housed internally within the muffler body and opening to the body interior.
A second plastic pipe extends into the hollow body and dead ends therein and is provided with perforations within the portion of the second pipe, interiorly of the hollow body. A mass of glass wool fibers fills the interior of the hollow body about the pipes and functions to assist in dampening the sound when the inlet ends of the first and second pipes are connected to positive air pressure exhausts leading from the first and second vacuum pumps. The exhaust from the second pipe passes outwardly from the dead ended second pipe through the perforations therein flowing through the glass wool and entering the perforations within the first pipe to mix commonly with the exhaust passing through the first pipe, prior to discharging to the atmosphere at the outlet end of the first pipe, exterior of the hollow body.
The hollow body is preferably of elongated cylindrical form, and both pipes are preferably L-shaped in configuration, the first pipe including a short length inlet portion projecting through one end of the elongated cylindrical body and forming the inlet for that pipe and having a longer portion extending nearly the full length of the elongated cylindrical body with an outlet end projecting through the opposite end wall of the body from that bearing the inlet portion. The perforations borne by the first pipe are within the long portion of the first pipe, internally of the body and just upstream of the point where the long portion projects through the body end wall. The second pipe is oppositely oriented, is provided with a short length inlet portion projecting through the long cylindrical wall of the body and terminates in a longer portion whose end remote from the inlet is closed off by an end plug and which end abuts the outside of the short length portion of the first pipe. The long portion of the second pipe is perforated upstream of the end plug such that the exhaust flows from the second pipe into the hollow body. The perforations of the first pipe and the second pipe are longitudinally offset to force the exhaust flow from the second pipe perforations to pass through a major extent of the glass wool filling the interior of the hollow plastic muffler body prior to entering the perforations of the first pipe and mixing with the exhaust flow from the first pump passing therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational view of a truck mounted hot water vacuum extraction machine utilizing the dual inlet muffler assembly forming a preferred embodiment of the present invention.
FIG. 2 is an enlarged, vertical sectional view of the muffler assembly for the machine illustrated in FIG. 1.
FIG. 3 is a cross-sectional view of the muffler assembly taken on line 3--3 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the muffler assembly of the present invention indicated generally at 10 has particular application to a large truck mounted hot water vacuum extraction system 12, of which the muffler assembly 10 comprises a part. The system 12 is mounted to a chassis 14 of truck 16. The truck chassis 14, behind cab 18, is shown as having a horizontal bed or platform 20 upon which the extraction system components are mounted. The illustrated system components do not comprise a complete system, however such systems are old per se and the components not shown have nothing to do with the muffling of the exhaust from multiple vacuum pumps incorporated within system 12. Further, the schematic representation is purely to illustrate the muffler as it applies to a large size mobile hot water vacuum extraction system. In that respect, the bed 20 has mounted thereon a rectangular box frame or stand indicated generally at 22 and comprised of a horizontal top wall 24 supported at its ends by legs 26. Mounted to top wall 24, in side-by-side fashion, are two tanks which are main components of system 12. The first is a cleaning liquid supply tank indicated generally at 28; the second being a vacuum pick up or dump tank 30. The cleaning liquid supply tank which may be formed of steel, as is tank 30, preferably includes internally a heater 32 for heating of cleaning liquid L which may comprise water bearing a suitable chemical cleaning composition or soap. A small diameter line 34 leads from tank 28 and incorporated within that line is a pump 36 for supplying the liquid L from the supply tank 28 to a spray nozzle 38 Nozzle 38 is mounted to a vacuum pick up head 40. Head 40 applys suction via a flexible hose 34a through a nozzle opening 40a to a limited area of the surface being cleaned for sucking up the cleaning liquid L after contact with the surface and any dirt entrained therein for return to the dump tank 30. In that respect, the vacuum pick up head 40 is fixedly mounted at one end of a wand 42 which is a hand held unit of tubular form whose opposite end is connected by way of larger diameter hose 44 to an inlet coupling 46 shown as being mounted to the dome shaped top 48 of dump tank 30. For the purposes of illustrating the nature and operation of the muffler assembly 10, the dump tank 30 is shown as including a riser tube 52 which rises vertically upward from the center of bottom wall 30a of the tank 30, being open at its upper end, and terminating short of dome 48.
Vacuum is applied to the bottom of riser tube 52 so as to bring down the pressure to a suitable degree of vacuum within tank 30 sufficient to promote a suction force at the suction nozzle opening 40a of the pick up head 40 to return cleaning liquid and entrained dirt to the dump tank 30. The dump tank 30 may in fact be rigidly fixed to the top 24 of frame 22 which supports that element and the accumulated dirty liquid L' within the tank may be drained through a drain pipe 30b opening to the tank interior through bottom wall 30a of that tank.
Conventionally in such systems, a vacuum pressure is applied to the interior of the dump tank by a single vacuum pump of suitable capacity. For the large truck borne system 12 to which the present invention has primary application, in order to quickly and efficiently obtain the desired vacuum pressure within the relatively large volume dump tank 30 which may be sized to receive hundreds of gallons of cleaning liquid and entrained dirt as at L', a pair of vacuum pumps are employed in parallel.
Schematically, in FIG. 1, a centrifugal blower or pump 54 is shown as being physically mounted on the top of a shelf 56 which forms a part of the frame 22 and which extends between longitudinally opposed and walls of that support 22. The shelf 5 is positioned somewhat below the top wall 24 of frame 22. The pump 54 may be a three stage centrifugal pump powered by a conventional Ametek Lamb motor 60. Motor 60 is electrically energized through electrical leads 62, from an electrical source (not shown). Additionally, a second positive displacement vacuum pump 58 is employed. The positive displacement pump 58, for example, could be a positive displacement blower of commercial design sold under the trade name "SUTORBILT" and employed as a second vacuum pump. Pump 58 is driven by an integral motor 64 which is energized via electrical leads 66 from the source. Such pumps necessarily include inlet and outlet pipes or tubes. Centrifugal pump 54 has an inlet pipe 68 leading thereto and an outlet pipe 70 leading therefrom. Positive displacement pump 58 is provided with an inlet or suction pipe 71 and an outlet pipe 72. The inlet pipes 68 for pump 54 and 71 for pump 58 are connected by way of a tee connection 74 directly to the riser tube 52 through a seal 76. Seal 76 may be integrated to dump tank 30 carried by bottom wall 30a. The function of seal 76 is to provide a coupling between tee 74 and riser tube 52 of the dump tank. Upon energization of the motors 60 and 64 for pumps 54 and 58, respectively, air at a pressure above atmospheric exits from pump outlet pipes 70 and 72 with considerable noise. Both pumps operate in parallel, and as illustrated, are connected commonly to the interior of the dump tank 30 via tee 74 and riser tube 52. It could be that centrifugal pump 54 and positive displacement pump 58 have their pump inlets connected separately to the interior of the dump tank 30.
The present invention is directed to the particular muffler assembly 10 for a truck mounted hot water vacuum extraction machine which muffles both the centrifugal pump 54 and the positive displacement pump 58, or their equivalents, and wherein there is a dual inlet to the muffler assembly and a single outlet. The structural content of muffler assembly 10 may be best seen by FIGS. 2 and 3 and its operation may be best appreciated by reference to those figures.
The dual inlet muffler assembly, as indicated generally at 10, is comprised of four principal components: an elongated cylindrical form hollow muffler body or housing indicated generally at 80; a first L-shaped exhaust pipe, indicated generally at 98 which passes completely through body 80; a second reversely oriented L-shaped exhaust pipe indicated generally at 100, also being carried by body 80; and a mass of glass wool 22 which fills the complete interior of the hollow body 80 with the exception of pipes 98 and 100.
The hollow muffler body 80, as wel as pipes 98 and 100, are formed of plastic, since such material is impervious to the moisture carried in the exhaust stream discharging from pumps 54 and 58. Likewise, the glass wool is impervious to moisture, thus, the muffler assembly will last indefinitely, being impervious to moisture.
The muffler body 80, in the elongated cylindrical form shown, is comprised of laterally opposed half cylinders 82 and 84, defining opposed side walls 86 and 88, respectively and end walls 90 and 92. Further, in the sectional view of FIG. 3, the body 80 is shown or formed of laterally joined, side by side mirror sections which are thermal bonded, adhesively sealed, or bolted together as shown to permit the insertion of pipes 98 and 100 as well as the glass wool 122. The halves are flanged at their edges as at 82a, 84a. The purpose of the body 80 is to provide an otherwise impervious hollow container within which the sound deadening or muffling occurs for the exhaust stream from pump 54 and pump 58 or their equivalents.
Reinforcing ribs 80a are integrally formed within the body sections or halves, 82, 84, by molding of the plastic body sections to give the desired rigidity to the housing. In the illustrated embodiment of the invention along with the flanges, the top of body 80, is provided with two circular holes as at 93 and 94, and end wall 90 is provided with a third circular hole as at 96 being sized to the components of exhaust pipes 98 and 100. The first exhaust pipe 98 consists of a short vertical pipe length or section 102 which functions as the the inlet 98a of this exhaust pipe. The vertical section 102 is joined to a much longer horizontal section 104 by means of a plastic elbow 106.
Elbow 106 has enlarged diameter collars or flanges 106a and 106b on opposite ends. Collar 106a sealably receives the end of the short length vertical pipe section 102 while collar 106b sealably receives the end of the relatively long horizontal pipe section 104. The horizontal pipe section 104 terminates outside of body 80, passing through opening 96 within end wall 92, forming the outlet end 98b of the exhaust pipe 98.
Important to the muffler action is the provision of a plurality of small diameter holes or perforations 108 within pipe section 104 just upstream of the point where it exits from the body 80. Those holes or perforations 108 are shown as being in row with the rows of perforations circumferentially spread completely about pipe 104. As may be appreciated, flow of exhaust gases from the centrifugal blower type pump 54 in a stream indicated by arrow 124, passes through exhaust pipe 98 with little frictional loss and little impedence. The exhaust stream, however, can interact with the sealed interior of muffler body 80 due to the presence of the perforations 108. Due to the presence of the glass wool 122 throughout the hollow body with the exception of that area occupied by exhaust pipes 98 and 100, the action substantially reduces the noise of the exhausting air.
Exhaust pipe 100 is formed of a vertical pipe section 110 which is coupled to a somewhat longer length horizontal pipe section 112 by elbow 114. Elbow 114 includes enlarged diameter flanges or collars as at 114a and 114b. The enlarged diameter flange 114a receives one end of vertical pipe section 110 internally within hollow body 80. Flange 114b receives one end of the horizontal pipe section 112. Pipe sections 112 terminates or dead ends at the side of vertical pipe or tube 102 of exhaust pipe 98. The end of exhaust pipe 100 is closed off by a thin circular disc or end plug 118 which may be formed of clear plastic and which is sized to and adhesively affixed to the end of pipe sections 112 remote from elbow 114. This may be achieved by using a screw 120 and fixing the disc 118 against the outside of vertical tube 102, whereupon the horizontal pipe section 112 is slid onto disc 118. A series of perforations or holes 116 are provided within the horizontal pipe section 112 over its full length, the holes 116 as illustrated are in rows and extend completely about the periphery of the tube 112 being spaced slightly from each other. In the case of exhaust pipe 100, however, due to that pipe being dead ended by disc 118 internally of housing 80, the exhaust stream 126 entering exhaust pipe 100 must in turn exhaust from the hollow body 80 via the first exhaust pipe 98.
As may be appreciated, the exhaust pipe components for pipes 98 and 100 remain in position after assembly. A second half 82 of the body 80 is otherwise sealably fixed to half 94 of that body after the interior is filled with glass wool 122. Arrows 128 show the exhaust stream entering the hollow interior of body 80 from perforations 116 of pipe section 112 and passing through the glass wool 122 towards the perforations or holes 108 carried by exhaust pipe 98. Arrows 130 show this air stream entering the interior of horizontal tube 104 through holes 108 and merging with the exhaust stream from the centrifugal blower or pump 124 as that stream flows towards the outlet end 98b of exhaust pipe 98, as indicated by arrows 132.
The muffler assembly 10 is shown as resting directly on the truck bed 20 although, of course, the assembly could be suspended by way of inlet ends 98a and 100a of exhaust pipes 98 and 100. The vertical pipe sections 102 and 110 could be connected directly to exhaust pipes 70 and 72 for pumps 54 and 58, respectively, or in fact constitute those exhaust pipes. Additionally, while the exhaust pipe 98 and the exhaust pipe 100 are shown as being L-shaped and reversely oriented, they may take other forms and they may be oriented differently although accomplishing the same purpose. It is preferred that a straight through design with little back pressure be employed for the exhaust pipe connected to the centrifugal pump or blower 54. Thus, pipe 98 could be a fully straight pipe and project through longitudinally opposed end walls 90 and 92 of the housing rather than as shown. Body 80 could be sectionalized elongated rectangular block form instead of cylindrical as shown.
While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the inven- tion.
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An elongated hollow plastic body mounts a first plastic exhaust pipe of L-shaped configuration which passes completely through the body. Its inlet end is connected to the positive air pressure discharge of one vacuum pump connected to a closed dirty water vacuum dump tank for the hot water vacuum extraction machine. A second plastic L-shaped exhaust pipe is reversely oriented within the hollow body and has a plugged end abutting the side of first pipe near its inlet to the body. Both pipes are perforated within portions internal of the body and the hollow body is filled with glass wool to muffle the sound. The second pipe at its inlet end, is connected to the positive pressure air discharging from a second vacuum pump also connected to the vacuum dump tank. The exhaust from the vacuum pumps is effectively muffled with the air discharging through the perforations upstream of the plugged end of the second pipe passing through the glass wool, entering the perforations in the first pipe, and mixing commonly with the exhaust air flow carried by the first pipe.
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BACKGROUND
The field of this disclosure relates to antimicrobial metal alloy compositions and especially to stainless steel alloys with antimicrobial properties
It is known that antimicrobial effects are shown by ions of mercury, silver, copper, iron, lead, zinc, bismuth, brass, gold, aluminum, and other metals. The technical paper; “Antibacterial Metals, a Viable Solution for Bacterial Attachment and Microbiologically Influenced Corrosion” by Kurissery et a provides an excellent overview of the importance of antimicrobial metals. Biofilm formation on surfaces is of concern to the public health. Also, biofilms are known to be deleterious to materials as they may induce corrosion. These reactions are referred to as biocorrosion or microbiologically influenced corrosion (MIC) when the underlying substratum is a metal or metal alloy. MIC is a serious problem in a number of industries including power generation, petrochemical, pulp and paper, gas transmission and shipbuilding. Conservative estimates place the direct cost of MIC at $30 to $50 billion per year at this time. The magnitude of the problem calls-for wider attention and collaboration between established research groups and laboratories that specialize in aspects of metal-microbe interactions. Such groups may focus on microbiology, metallurgy, civil & environmental engineering and biotechnology.
Stainless steel is widely used for architectural and decorative applications such as hand rails, faucets and other objects that receive continuous human contact. Stainless steel surfaces have no known antimicrobial effect. In the prior art we find that a small amount of copper is known to have been included as a constituent of stainless steel to achieve antimicrobial effects, but this approach is relatively expensive due to the cost of copper and the extra steps required in processing. Another problem is that such alloys exhibit lower corrosion resistance. Silver has also been used in stainless steel alloys but suffers the same issues as copper. Antimicrobial features in stainless steels have been shown to be effective against: Escherichia coli, Candida Albicans , HIV, and others microbes and viruses.
Antimicrobial coatings are known in the art as exemplified by U.S. Pat. No. 6,929,705 to Myers et al wherein a liquid dispersion containing metal component-supporting oxides and zeolite powders is applied to metal parts. Laminations such as taught in U.S. Pat. No. 7,521,489 to Shimazaki have been used wherein an antibacterial metal such as silver is used with layers of structural metals such as steel.
BRIEF SUMMARY AND OBJECTIVES
The presently disclosed stainless steel has alloying components that produce an antibacterial property, corrosion resistance and improved processability. Microscopic observations, quantitative bacteriostasis and selective mechanical tests show that a trace addition of an antibacterial alloying agent can homogeneously distribute in a 304 stainless steel matrix and can slightly improve its corrosion resistance. With an increase in the alloying addition, in some alloys clustering may occur, which reduces corrosion resistance and processability due to immiscible alloying constituents. Antibacterial additions in some stainless steel alloys exhibits the hormesis effect against staphylococcus aureus ( S. Aureus ) wherein a small addition may stimulate growth. In general, the greater the addition of the antibacterial agent, the better the antibacterial capability of the alloy.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates samples showing antibacterial colonies indicating the effect of various levels of an antibacterial alloying component in 304 stainless steel; and
FIG. 2 illustrates topographies of the est specimens.
DETAILED DESCRIPTION
An austenitic stainless steel alloy (the alloy) and its processing method is described. The alloy provides high strength, is highly corrosion resistant, and has strong antimicrobial properties while being able to be produced at a competitive cost. The alloy may comprise constituents of: iron, carbon, chrome, manganese, nickel, nitrogen, phosphorus, silicon, sulfur, molybdenum, copper, and tin in various amounts, and may include an antimicrobial compound (AC) which may be a mischmetal having Ce 70% and La 30% with these percentages being approximate ±10%, and may also include a grain refiner consisting of Cu 95% and Sn 5%, again approximately. In order to test the antimicrobial effectiveness of test specimens the alloy was produced and evaluated as described below.
Samples were produced using investment casting, and were solution treated at about 1050 degrees centigrade for about 30 minutes. Cast rods were sectioned and machined to produce disc specimens 25 mm in diameter and 2 mm in thickness. The specimens were polished and then cleaned using an ultrasonic bath.
For testing, the discs were sterilized by first autoclaving and then subjecting them to ultraviolet radiation. A thin film quantitative bacteriostasis method was used to evaluate antimicrobial performance according to the JIS z 2801-2000 (Japanese Industrial standard). A test strain of staphylococcus (s) aureus was introduced into a nutrient broth containing peptone and beef extract and then thoroughly homogenized mechanically to produce a microbial suspension. The suspension was diluted using a PbS buffer solution to produce a test material.
Fifty micro-liters of the test material was placed on each disc and then covered with a petri-slide allowing the test material to spread uniformly over the disc as a fluid thin film. Control samples were handled in the same manner substituting distilled water for the test material. All of the discs were held in an environmental chamber for 24 hours at 37° C. at over 90% relative humidity. Each specimen was then thoroughly washed with a highly dilute solution of the PbS buffer. An agar plate method was used to culture and perform a count of live microbes on each disc. All tests were carried out in triplicate. The relative sterilization rate of the microbes was calculated using:
R (%)=( C−A )/ CX 100%
Where R is the relative sterilization rate, C is the mean number of individual microbes counted on a control disc and A is the mean number of individual bacteria counted on a test disc. FIG. 1 shows the growth of s. Aureus on the discs. By counting the microbial colony numbers on each disc the effect of various percentages of the antimicrobial compound (AC) were estimated.
Results are shown below:
AC %
R
0
—
0.050
−7.3
0.15
24.2
0.30
69.5
0.40
99.3
The following alloy partials were found to be effective in meeting the objectives, including alloying elements: Fe, Cr, Ni, Cu, and a mischmetal of at least 0.3 wt. %. Further, this alloy wherein the mischmetal includes about 70 wt. % Cu and 30 wt. % La. Further, this alloy with a grain refiner comprising Cu 95 wt. % and Sn 5 wt. %. Further, this alloy with at least one element selected from the group of elements consisting of carbon, manganese, nitrogen, phosphorus, silicon, sulfur, molybdenum, and tin. Further, wherein the Fe is at about 60 wt. %. Further, wherein the Cr is not more than 20 wt. %. Further, wherein the Ni is not more than 12 wt. %, and further wherein the Cu is not more than 2 wt. %.
In an alternate embodiment the antimicrobial stainless steel alloy may comprise by weight percent: up to 0.150 C, up to 20 Cr, up to 2.0 Mn, up to 12 Ni, up to 0.045 P, up to 1.0 Si, up to 0.030 S, 0.38 to 0.5 Ce, 1.48 to 3.1 Cu, 0.008 to 0.113 Sn and the balance Fe and impurities, and further comprising a mischmetal of at least 0.3 wt. %. The Ni may comprise not more than 10.5 weight percent, the Si may comprise not more than 0.75 weight percent, the N may comprise not more than 0.10 weight percent, the N may comprise between 0.10 and 0.16 weight percent and may alternately comprise between 0.16 and 0.30 weight percent. The C may comprise not more than 0.070 weight percent, while CR may comprise from 12.0 to 19.0 weight percent, and Ni may comprise not more than 14.0 weight percent, with Mo of not more than 3.0 weight percent.
Our conclusion is that the alloy does not exhibit any antimicrobial improvement when AC % is below 0.04; while instead, stimulated microbial growth is apparent. As the AC % increases however, the alloy gradually exhibits an antibacterial effectiveness. When the AC % is close to 0.38 sterilization efficiency is more than 99%, exhibiting an excellent antimicrobial effect. Our conclusion is also that we have discovered a means for producing stainless steel alloys that extinguish antimicrobial elements on their surfaces effectively without causing degradation to the fabricated article and without unreasonably increasing the cost of manufacture.
Embodiments of the subject apparatus and method have been described herein. Nevertheless, it will be understood that modifications may be made without departing from the spirit and understanding of this disclosure. Accordingly, other embodiments and approaches are within the scope of the following claims.
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An austenitic antibacterial stainless steel formulation provides a high strength, highly corrosion resistant, antimicrobial product at a relatively low cost wherein antimicrobial performance is dramatic and greater mechanical properties and corrosion resistance are achieved as well. The alloy may comprise key constituents of Fe, Cr, Ni, and C plus a mischmetal having Ce and La components.
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CLAIM OF PRIORITY
[0001] This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application for FIELD EMISSION DEVICE AND BACKLIGHT DEVICE USING THE SAME earlier filed in the Korean Intellectual Property Office on 9 Feb. 2004 and there duly assigned Serial No. 10-2004-0008341.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a field emission device and a backlight device using the field emission device and a method of manufacture thereof, and more particularly, to a field emission device employing Carbon NanoTubes (CNTs) and a backlight device using the field emission device and a method of manufacture thereof.
[0004] 2. Description of the Related Art
[0005] In general, flat panel displays are roughly classified into light emitting displays and light receiving displays. The light emitting type displays include Cathode Ray Tubes (CRTs), plasma display panels (PDPs), Field Emission Displays (FEDs), and the like. The light receiving displays include Liquid Crystal Displays (LCDs). The LCDs are light in weight and consume little electric power. However, LDCs themselves cannot emit light to form images. They can form images by using light entering from the outside. Thus, it is impossible to observe the images in a dark place. To overcome this problem, backlight devices are installed in the back of the LCDs.
[0006] In the Past, Cold Cathode Fluorescent Lamps (CCFLs), which are line light sources, and Light Emitting Diodes (LEDs), which are point light sources, were mainly used as backlight devices. However, in general, such backlight devices have a complicated construction, thereby being quite expensive. Furthermore, light sources are disposed in the lateral sides of the backlight devices and thus, due to the reflection and transmission of light, consumption of electrical power increases. Especially, as LCDs become larger, it becomes more difficult to ensure uniform brightness of a backlight device.
[0007] Accordingly, to overcome the above problems, field emission backlights having a light emitting structure in a plate configuration have been suggested. The field emission type backlight devices consume less electrical power than backlight devices such as cold cathode fluorescent lamps. Furthermore, they advantageously have relatively uniform brightness even with a large light emitting area.
[0008] In a field emission backlight device, a top substrate and a bottom substrate are disposed opposite to each other and spaced apart from each other by a predetermined distance. An anode electrode and a fluorescent layer are sequentially formed on an inner surface of the top substrate. A cathode electrode is formed on an upper surface of the bottom substrate. A gate insulating layer having a through hole is formed on the cathode electrode. A gate electrode is formed on the gate insulating layer, and the gate electrode has a gate hole, which corresponds to the through hole. CNT emitters are formed on an exposed surface of the cathode electrode through the through hole.
[0009] For the field emission type backlight device having the above structure, when a voltage V a of several kilovolts is supplied to the anode electrode and a voltage V g of several tens of volts is supplied to the gate electrode, electrons are emitted from the CNT emitters toward the anode electrode. The electrons excite the fluorescent layer to emit visible light.
[0010] The CNT emitters can be produced by screen printing a paste containing CNTs on the exposed surface of the cathode electrode through the gate hole, followed by etching.
[0011] However, the density of the CNT emitters produced by the screen printing method is low, thereby causing a problem in obtaining a field emission device having a high brightness.
[0012] Moreover, the field emission device having the layered structure noted above needs repetitive patterning, which results in high production costs.
SUMMARY OF THE INVENTION
[0013] The present invention provides a field emission device having a high density of CNT emitters and a backlight device using the field emission device.
[0014] The present invention also provides a field emission device manufactured by a simple process in which a cathode electrode and a gate electrode are disposed on the same plane, and a backlight device using the field emission device.
[0015] According to an aspect of the present invention, a field emission device is provided comprising: a cathode electrode and a gate electrode formed in alternating parallel strips on a substrate; a catalytic metal layer formed on the cathode electrode and adapted to enhance carbon nanotube (CNT) growth ; and grown CNTs arranged on the catalytic metal layer.
[0016] The catalytic metal layer adapted to enhance carbon nanotube (CNT) growth can be discontinuously formed on the cathode electrode.
[0017] Alternatively, the catalytic metal layer adapted to enhance carbon nanotube (CNT) growth can be continuously formed on the cathode electrode.
[0018] The catalytic metal layer adapted to enhance carbon nanotube (CNT) growth can be composed of at least one metal selected from the group consisting of Ni, Co, Fe and inbar.
[0019] According to another aspect of the present invention, a field emission backlight device is provided comprising: a top substrate and a bottom substrate disposed in parallel and spaced apart from each other by a predetermined distance; an anode electrode formed on the top substrate; a fluorescent layer formed on the anode electrode and having a predetermined thickness; a cathode electrode and a gate electrode formed in alternating parallel strips on the bottom substrate; a catalytic metal layer formed on the cathode electrode and adapted to enhance CNT growth; and grown CNTs arranged on the catalytic metal layer.
[0020] According to yet another aspect of the present invention, a method of manufacturing a field emission device is provided, the method comprising: arranging a cathode electrode and a gate electrode in alternating parallel strips on a substrate; arranging a catalytic metal layer on the cathode electrode to enhance Carbon NanoTube (CNT) growth ; and growing CNTs on the catalytic metal layer.
[0021] The catalytic metal layer can be discontinuously arranged on the cathode electrode.
[0022] Alternatively, the catalytic metal layer can be continuously arranged on the cathode electrode.
[0023] The catalytic metal layer can be composed of at least one metal selected from the group consisting of Ni, Co, Fe, and inbar.
[0024] According to still another aspect of the present invention, a method of manufacturing a field emission type backlight device is provided, the method comprising: arranging a top substrate and a bottom substrate in parallel and spaced apart from each other by a predetermined distance; arranging an anode electrode on the top substrate; arranging a fluorescent layer on the anode electrode, the fluorescent layer having a predetermined thickness; arranging a cathode electrode and a gate electrode in alternating parallel strips on the bottom substrate; arranging a catalytic metal layer on the cathode electrode to enhance CNT growth; and growing CNTs on the catalytic metal layer.
[0025] The catalytic metal layer can be discontinuously arranged on the cathode electrode.
[0026] Alternatively, the catalytic metal layer can be continuously arranged on the cathode electrode.
[0027] The catalytic metal layer can be composed of at least one metal selected from the group consisting of Ni, Co, Fe, and inbar.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] A more complete appreciation of the present invention, and many of the attendant advantages thereof, will be readily apparent as the present invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
[0029] FIG. 1 is a partial cross-sectional view of a field emission type backlight device;
[0030] FIG. 2 is a schematic cross-sectional view of a backlight device according to an embodiment of the present invention;
[0031] FIG. 3 is a schematic top view of a field emission device of FIG. 2 according to another embodiment of the present invention; and
[0032] FIG. 4 is a schematic top view of a modification of a field emission device according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIG. 1 is a partial cross-sectional view of a field emission type backlight device.
[0034] Referring to FIG. 1 , a top substrate 20 and a bottom substrate 10 are disposed opposite to each other and spaced apart from each other by a predetermined distance. An anode electrode 22 and a fluorescent layer 24 are sequentially formed on an inner surface of the top substrate 20 . A cathode electrode 12 is formed on an upper surface of the bottom substrate 10 . A gate insulating layer 14 having a through hole 14 a is formed on the cathode electrode 12 . A gate electrode 16 is formed on the gate insulating layer 14 , and the gate electrode 16 has a gate hole 16 a corresponding to the through hole 14 a . CNT emitters 30 are formed on an exposed surface of the cathode electrode 12 through the through hole 14 a.
[0035] For the field emission type backlight device having the above structure, when a voltage V a of several kilovolts is supplied to the anode electrode 22 and a voltage V g of several tens of volts is supplied to the gate electrode 16 , electrons are emitted from the CNT emitters 30 toward the anode electrode 22 . The electrons excite the fluorescent layer 24 to emit visible light 26 .
[0036] The CNT emitters 30 can be produced by screen printing a paste containing CNTs on the exposed surface of the cathode electrode 12 through the gate hole 16 a, followed by etching.
[0037] However, the density of the CNT emitters 30 produced by the screen printing method is low, thereby causing a problem in obtaining a field emission device having a high brightness.
[0038] Moreover, a field emission device having the layered structure noted above needs repetitive patterning, resulting in high production costs.
[0039] Hereinafter, a field emission device and a backlight device according to exemplary embodiments of the present invention will be described in detail with reference to the attached drawings. In the drawings, the size of layers and zones has been exaggerated for clarity.
[0040] FIG. 2 is a schematic cross-sectional view of a backlight device according to an embodiment of the present invention. FIG. 3 is a schematic top view of the field emission device of FIG. 2 according to an embodiment of the present invention.
[0041] Referring to FIGS. 2 and 3 , a top substrate 120 and a bottom substrate 110 are disposed opposite to each other and spaced apart from each other by a predetermined distance. An anode electrode 122 and a fluorescent layer 124 are sequentially formed on an inner surface of the top substrate 120 . A field emission device is formed on an upper surface of the bottom substrate 110 .
[0042] In the field emission device, a cathode electrode 112 and a gate electrode 116 are formed in alternating parallel strips on the bottom substrate 110 . The cathode electrode 112 and the gate electrode 116 can be obtained by depositing Cr or ITO on the bottom substrate 110 , followed by patterning.
[0043] The gate electrode 116 extract electrons from CNT emitters 130 formed on the cathode electrode 112 therebetween. A voltage V g of several tens of volts, for example, 40 V, is supplied to the gate electrode 116 .
[0044] A thin metallic film 113 is formed on the cathode electrode 112 . The thin metallic film 113 is a catalytic metal layer added to enhance CNT growth and is composed of at least one metal selected from the group consisting of Ni, Co, Fe and inbar. The thin metallic film 113 can have a thickness of about 1 μm.
[0045] The thin metallic film 113 can be discontinuously formed on the cathode electrode 112 of FIG. 3 . However, the present invention is not limited thereto. That is, referring to FIG. 4 , the thin metallic film 113 can be continuously formed on the cathode electrode 112 . The discontinuous metallic film of a predetermined size can be formed by a surface mounting technique, such as chip mounting. The continuous metallic film 113 can be formed by heat transfer.
[0046] The CNT emitters 130 are formed on the thin metallic film 113 . The CNT emitters 130 are obtained by disposing the bottom substrate 110 on which the thin metallic film 113 is formed in a chamber at a predetermined temperature, for example, 750° C., and injecting a carbon-containing gas into the chamber to grow carbon nanotubes from the surface of the thin metallic film 113 . Methane (CH 4 ), acetylene (C 2 H 2 ), ethylene (C 2 H 4 ), ethane (C 2 H 6 ), carbon oxide (CO), carbon dioxide (CO 2 ) and so on can be used as the carbon-containing gas.
[0047] The CNT emitters 130 can be formed with high density on the thin metallic film 113 depending on the adsorption time of carbon.
[0048] Referring to FIG. 2 , a voltage V g of 40 V is supplied to the gate electrode 116 and a voltage V a of 2 kV is supplied to the anode electrode 122 . Then, electrons are emitted from the CNT emitters 130 and proceed toward the anode electrode 122 and collide with a fluorescent layer 124 . Visible light 126 is generated by the fluorescent layer 124 . Then, the visible light 126 passes through the top substrate 120 .
[0049] In the field emission device according to an embodiment of the present invention, the CNT emitters can be formed with an increased density on the cathode electrode, thereby enhancing an electron-emitting capacity of the CNT emitters. Thus, the backlight device using the field emission device exhibits a high brightness.
[0050] In addition, in the field emission device according to an embodiment of the present invention, the gate electrode can be manufactured by a simple process in which a cathode electrode and a gate electrode are disposed on the same plane. Thus, the field emission type backlight device can be manufactured at a low cost.
[0051] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details can be made therein without departing from the spirit and scope of the present invention as defined by the following claims.
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A field emission device and a backlight device using the field emission device includes a cathode electrode and a gate electrode formed in alternating parallel strips on a substrate, a catalytic metal layer arranged on the cathode electrode and adapted to enhance Carbon NanoTube (CNT) growth, and grown CNTs arranged on the catalytic metal layer.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit to U.S. provisional application Ser. No. 60/617,298 filed Oct. 8, 2004.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Technical Field
[0004] The present invention relates to turbine engines, and in particular, to valves for relieving high pressure transients in the liquid fuel side of the turbine.
[0005] 2. Description of the Related Art
[0006] Turbine engines are commonly used in power generation and propulsion applications. Generally, turbine engines have a set of rotating turbine blades that compress air leading to one or more combustors into which fuel is injected and ignited. Fuel is delivered through metering orifices to burners in the combustors under pressure through one or more fuel lines. Combustion of the fuel turns one or more sets of turbine blades, used for energy extraction or propulsion, and which can be used to drive the compressor blades.
[0007] Modern industrial gas turbines used for power generation are commonly operable in either liquid fuel (such as diesel fuel) and gaseous fuel (such as natural gas) modes. Such gas turbines thus include both a liquid fuel system and a gaseous fuel system. Due to their respective burn characteristics, typically, liquid fuel is consumed for turbine start-up and gaseous fuel is consumed for sustained operation of the turbine.
[0008] The pressure in each of the liquid and gaseous fuel systems can fluctuate during operation of the turbine and high pressure transients can arise. This is particularly a problem in the liquid fuel system given that liquids are generally not compressible. Elevated pressures commonly arise in the liquid fuel system during certain stages of turbine operation.
[0009] First, since liquid fuel is typically consumed during turbine start-up, the pressure in the liquid fuel system will rise significantly after ignition. During the start-up stage, the elevated pressure in the liquid fuel system is necessary to sustain burning. Thus, normally pressure loss in this stage is unwanted. Second, when the turbine is to be shut down or transitioned to operate in gaseous mode, high pressure transients can occur in the liquid fuel system due to the back flow of fuel back into the system caused by the shutting down of various pumps and metering devices, such fuel pumps, flow dividers, distributor valves and purge valves, in the liquid fuel system. Third, after the turbine is switched to burn gaseous fuel, the ambient temperature surrounding the turbine rises due to the heat given off by the sustained operation of the turbine. This increase in temperature can cause expansion of the liquid fuel and increase the pressure within the liquid fuel system. These thermal pressure transients must be relieved.
[0010] Check valves are typically installed in communication with the liquid fuel system to regulate flow to a drain line and thus relieve the pressure in the liquid fuel system. The check valves are disadvantageous because they are one-way valves that open and close at a particular crack pressure and then return closed after the pressure subsides. Thus, a check valve will remain open as long as the pressure is at or above the crack pressure. However, as mentioned above, depending upon the stage of operation, it may be necessary to maintain pressure at a value higher than the crack pressure of the check valve, for example, during start-up. A single check valve would thus be insufficient for this purpose. Additionally, common check valves are spring-loaded ball valves that may be unreliable in the harsh environment of large industrial turbines, particularly given the contaminants present in the liquid fuel and the propensity for coking. Thus, such check valves may stick in the open position or allow backwash into either of the fuel lines.
[0011] The main fuel control valve that controls fuel flow in the liquid fuel system may be used instead to relieve pressure. However, the fuel cut-off valve is usually operated by a pneumatic actuator and thus is impractical for relieving pressure transients because of its difficultly to control precisely and because it would likely introduce a substantial pressure drop. Like check valves, it is also subject to coking due to its relatively close position to the combustion area of the turbine. Moreover, the fuel cut-off valve would also introduce a potential failure point to the turbine where, if pressure is lost to the pneumatic actuator, the turbine could cease operating.
[0012] Accordingly, an improved relief valve is needed that will relieve pressure transients, but also maintain pressure in the liquid fuel system when needed during various stages of turbine operation.
SUMMARY OF THE INVENTION
[0013] The present invention is a bi-stable valve that is particularly suited for relieving pressure that can build up in the liquid side of the fuel system of a turbine engine during various stages of operation of the turbine. In particular, the valve works to relieve thermal high pressure transients while preventing significant pressure losses during turbine start-up and sustained operation.
[0014] Generally, the valve includes a moveable valve member that toggles between one of two closed positions to interrupt flow through the valve when below a lower pressure limit and when above an upper pressure limit. The valve member moves to an intermediate position temporarily to relieve pressure transients within the pressure limits.
[0015] More specifically, in one aspect the invention provides a bi-stable valve for use in the fuel system of a turbine engine to relieve pressure between lower and upper pressure limits. The valve has a valve member, such as a poppet, that toggles between two closed positions in which flow from an inlet to an outlet is interrupted. The poppet biased in one of he closed positions at least until the lower pressure limit is reached at the inlet. It is moved into to the second closed position after the upper pressure limit is reached. The poppet moves to an intermediate (open) position between the two closed positions when the inlet pressure is between the limits to permit flow from the inlet to the outlet.
[0016] The valve can be use the media that it controls to drive, at least in part, the poppet or other valve member. In one preferred application, the media is liquid fuel, and in that case, the valve can be said to be “fueldraulic” in that fuel is used to actuate the valve. In one preferred case, a biasing member, such as a spring, can bias the poppet in the first closed position corresponding to below the lower pressure limit, and the fuel can move the poppet against this bias to open the valve and to re-seat the poppet in the second closed position corresponding to above the upper pressure limit.
[0017] In one preferred form the valve includes a housing defining a passageway between the inlet and outlet. Two seals, such as o-rings, are disposed about the passageway at an axial distance from each other. The valve member is disposed between the seals to intersect the passageway. The valve member can toggle between two closed positions in which the valve member seats against one seal one closed position in which the valve member is seated against one of the seals to close off flow to the outlet being. A biasing member, such as a compression spring, biases the valve member in contact with one of the seals where it stays until a crack pressure is reached. The valve member is moved between its biased state, preferably under the force of the controlled media, to in between the seals so that flow can pass to the outlet. When a close pressure is reached at the valve inlet, the valve member is moved into the second closed position, again preferably under the force of the controlled media, to re-close flow to the outlet.
[0018] The valve member is preferably a poppet valve. It can have a disk-shape with a leading face that seats against one seal and a trailing face that seats against the other seal. The poppet can also be disposed within an opening defined by a narrowed neck of the housing. When the poppet is open, fuel or other media can flow through from the inlet through the space between the poppet and the neck of the housing. The narrowed neck allows the neck opening size to be bore to a controlled dimension as needed to achieve the desired flow characteristics. To prevent the poppet from becoming cocked and possibly locking against the neck, the poppet can have a rounded periphery and an elongated stem that guides and limits non-axial movement of the valve member between the closed positions. The stem can extend axially into the passageway and engage an internal part of the housing.
[0019] Also, the spring pre-loads the poppet to the first closed position. The pre-load force determines the operating range of the valve, that is the upper and lower pressure limits that will cause seating, opening, and re-seating of the poppet. The pre-load force is dependent upon the spring rate and pre-compression of the spring. To allow for quick and easy adjustment of the pre-compression, one or more spacer rings (of the same or differing thicknesses) can be placed between an end of the spring and the abutting structure. For example, one or more spacers can be disposed between non-poppet end of the spring and a spring retainer.
[0020] In another aspect the invention provides a method of operating a valve as described above. According to this method, when the inlet pressure is below a lower pressure limit, the poppet is biased to seat against a first seal and close of a passageway between an inlet and an outlet. When it is above an upper pressure limit, the media that is controlled by the valve (e.g., liquid fuel) is used to seat the poppet against a second seal and close of the passageway. When within the pressure limits, the controlled media moves the poppet to an intermediate position between the seals to allow the controlled media to pass from the inlet to the outlet.
[0021] These and other advantages of the invention will be apparent from the detailed description and drawings. What follows is a preferred embodiment of the present invention. To assess the full scope of the invention the claims should be looked to, as the preferred embodiment is not intended as the only embodiment within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of a thermal relief valve of the present invention;
[0023] FIG. 2 is a sectional view thereof taken along line 2 - 2 of FIG. 1 ;
[0024] FIG. 3 is an enlarged partial sectional view showing the valve of FIG. 1 in a first closed state;
[0025] FIG. 4 is a view similar to FIG. 3 albeit showing the valve in an intermediate, open state; and
[0026] FIG. 5 is a view similar to FIG. 3 albeit showing the valve in a second closed state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] The present invention provides a relief valve 10 (see FIG. 1 ) particularly suited for use with dual fuel turbines in which the turbine consumes either liquid or gaseous fuel at one or more stages of operation. Such turbines are typically large industrial turbines used for power generation, and they typically burn liquid fuel (such as diesel fuel) during start-up and switch to gaseous fuel (such as natural gas) during sustained operation. In this context, the relief valve 10 is used to relieve transient high pressure in the liquid fuel system of the turbine, which can occur at start-up, the transition to gaseous fuel and as the liquid fuel is heated by the elevated ambient temperature surrounding the combustion areas of the turbine during operation on gaseous fuel. The valve is normally closed at turbine ignition when liquid fuel is used and during the dynamic transfer from gaseous to liquid fuel usage, and can be opened when high pressure transients arise during gaseous fuel operation to drain fuel and alleviate the high pressure.
[0028] FIGS. 1 and 2 illustrate one preferred embodiment of the relief valve 10 of the present invention. As shown, the preferred relief valve 10 includes an elongated tubular housing 12 concentric about axis 14 with flanged end fittings 16 and 18 . Four long bolts 20 and self-locking nuts 22 clamp the end fittings 16 and 18 to the housing 12 . The end fittings 16 and 18 are sealed by o-rings 24 at an inside surface of the housing 12 . The end fittings 16 and 18 define threaded recesses into which annular retainer nuts 26 are threaded to retain filters 28 , which are preferably low pressure drop open weave type filters.
[0029] End fitting 16 has an opening 30 , extending along the axis 14 through a short neck 32 , and thus provides an inlet port. End fitting 18 also has an opening 34 , which is defined by an elongated body 36 having a short neck 38 , and thus provides an outlet port. Two o-rings 40 are disposed about each of the necks 32 and 38 . The inlet o-ring is captured between chamfered surfaces of the neck 32 and a seat ring 42 , and the outlet o-ring is captured by chamfered surface of the neck 38 and an annular spring retainer 44 , which fits onto the body 36 of the outlet end fitting 18 and has a flange 46 that captures a compression spring 48 . The spring retainer 44 compresses the spring 48 to effect a pre-load. One or more ring spacers 49 can be placed between the spring retainer flange 46 and the associated end of the spring 48 to allow for selectively adjusting the pre-compression to effect a desired pre-load.
[0030] The spring 48 presses against a poppet 50 that is moveably captured between the end fittings 16 and 18 and a narrowed neck 52 of the housing 12 . The poppet 50 is disposed at the narrowed neck 52 to ease manufacturing by allowing the neck to be simply bored to a controlled dimension necessary to effect the desired flow characteristics. The poppet 50 is a generally flat round, disk-shaped piece with an elongated pilot stem 51 that extends into the opening 34 of the outlet end fitting 18 . The pilot stem 51 extends generally axially and its enlarged trailing end 53 engages the inner diameter of the outlet end fitting 18 to limit non-axial movement of the poppet 50 . Since the opening 34 is part of the drain passageway, the length of the pilot stem 51 is kept more narrow and the end 53 has axial passages 55 (one shown) so as not to disrupt flow. Also, the periphery of the poppet is slightly rounded over in the axial direction, thereby providing another anti-cocking feature, and also easing flow between the poppet 50 and the housing neck 52 .
[0031] A passageway 54 is thus formed within the relief valve 10 between the opening 30 of the inlet end fitting 16 , the gap between the end fittings 16 and 18 and the opening 34 of the outlet end fitting 18 . The relief valve 10 can thus be coupled between the fuel side of the turbine and the drain to relieve excess pressure in the liquid fuel system by opening the poppet 50 so that fuel can pass into and through the passageway 54 to the drain.
[0032] The relief valve is a bi-stable valve in that it is designed to seat and hold seated the poppet 50 so as to close off the outlet to drain in two steady-state conditions, namely, when the pressure at the inlet side of the relief valve 10 is below a lower pressure limit (or crack pressure) and when the pressure at the inlet side of the relief valve 10 is above an upper pressure limit (close pressure). In one preferred form, this operational pressure range of the relief valve 10 has a lower pressure limit of 150 psig +/−10 psig and an upper pressure limit of 160 psig +/−10 psig, and the relief valve 10 is capable of operating with at least as little as only a 5 psig pressure differential between the limits.
[0033] More specifically, as shown in FIGS. 3-5 , the inlet side face of the poppet 50 abuts the o-ring 40 on the inlet end fitting 16 and creates a face seal therewith to close off flow through the passageway 54 to the outlet. This closed position shown in FIG. 3 is the normal, de-energized state of the relief valve 10 , and it is held in this state by the spring 48 . The spring 48 provides a pre-load force that ensures a tight seal throughout the low pressure operational range of the relief valve 10 . Once the lower pressure limit (crack pressure) is reached, the hydraulic force of the liquid fuel acting on the inlet face of the poppet 50 will overcome the spring force of the spring 48 and move the poppet 50 axially toward the outlet end fitting 18 . This has the effect of unseating the poppet 50 from the inlet o-ring 40 to open up flow through the passageway 54 to the outlet. As shown in FIG. 4 , the fuel can flow through the opening 30 in the inlet end fitting 16 , turn radially to flow along the inlet face of the poppet 50 , turn again to flow around the periphery of the poppet 50 , turn another time to flow along the outlet side of the poppet 50 , and then turn one last time to axially through the opening 34 of the outlet end fitting 18 where it can pass out of the relief valve 10 to the drain. Since the poppet 50 is actuated by the hydraulic force liquid and the liquid is fuel, the relief valve 10 can be said to be a “fueldraulic” relief valve. The use of the fuel as the primary moving media eliminates the need for air, water, oil or other media lines, thereby reducing cost, size and complexity of the valve.
[0034] Once the upper pressure limit (close pressure) is reached, the poppet 50 will seat against the outlet side o-ring to once again close off flow to the outlet, as shown in FIG. 5 . Once the pressure of the fuel flow subsides sufficiently, the force of the spring 48 will reseat the poppet 50 to seal against the o-ring 40 of the inlet end fitting 16 , as shown in FIG. 3 .
[0035] Thus, the relief valve 10 is designed to toggle between one of two closed positions to close off flow to the drain in one of two pressure conditions (below the lower pressure limit and above the upper pressure limit), while moving through intermediate positions between the two closed positions to open and allow for pressure relief when the pressure conditions are between the lower and upper limits. The operational characteristics of the relief valve 10 thus make it suitable for use with liquid fuel system of the turbine during all stages of operation of the turbine. In particular, the relief valve 10 will close off the liquid fuel system from the drain when the turbine is shut down. At start-up when liquid fuel is burned, the pressure will increase rapidly in the liquid fuel system and pressurize the relief valve 10 above the upper pressure limit, thereby causing the poppet to toggle to the second closed position of FIG. 5 . The relief valve 10 will thus avoid pressure loss in the liquid fuel system during liquid fuel consumption, although there will be very minor fuel flow to drain as the poppet 50 toggles from the position of FIG. 3 to the position of FIG. 5 .
[0036] After start-up, the turbine is typically transitioned dynamically to burn gaseous fuel for sustained operation. The liquid fuel system is thus shut down so that pressure in the relief valve 10 will fall below the upper pressure limit, which thereby causes the poppet 50 to toggle to the first closed position of FIG. 3 . During the transition to gaseous fuel, the actuating members (pistons, spools, etc.) of the liquid fuel pump, the purge valve and other such components of the turbine fuel system return to a null position to close down liquid fuel flow to the turbine. This can cause a back flow of fuel and thereby a pressure build-up in the liquid fuel system. Should this pressure rise above the lower pressure limit, the poppet 50 would move to an intermediate position between the o-rings 40 to open and stay open as long at the conditions were between the lower and upper pressure limits.
[0037] Once the turbine is operating in gaseous mode and the liquid fuel system is shut down, the relief valve 10 will be in the closed state of FIG. 3 . The sustained operation of the turbine will raise the ambient temperature where the liquid fuel system is located. The elevated ambient temperatures can cause thermal expansion of the liquid fuel and thereby raise the pressure inside the liquid fuel system. As high pressure transients rise above the crack pressure, the poppet 50 will unseat from the inlet side o-ring to open the liquid fuel to the drain. Typically, the poppet 50 will open momentarily and reseat (on the inlet side o-ring) in a perking action to expel small, intermittent volumes of fuel to the drain. The relief valve 10 will thus continuously relieve thermal high pressure transients during sustained gaseous operation of the turbine.
[0038] Accordingly, the bi-stable valve of the present invention can be operated according to the following method or system. When the inlet pressure is below a lower pressure limit, the poppet is biased to seat against a first seal and close of a passageway between an inlet and an outlet. When it is above an upper pressure limit, the media that is controlled by the valve (e.g., liquid fuel) is used to seat the poppet against a second seal and close of the passageway. When within the pressure limits, the controlled media moves the poppet to an intermediate position between the seals to allow the controlled media to pass from the inlet to the outlet.
[0039] It should be appreciated that merely a preferred embodiment of the invention has been described above. However, many modifications and variations to the preferred embodiment will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced.
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A valve for the fuel system of a turbine engine works to relieve high pressure transients in the liquid fuel side of the turbine engine arising from the elevated ambient temperatures of operation of the turbine on gaseous fuel. The valve also prevents significant pressure losses during turbine start-up and sustained operation. The valve is bi-stable and has a liquid fuel driven poppet that toggles between one of two closed positions to interrupt flow through the valve when below a lower pressure limit and when above an upper pressure limit. The poppet moves to an intermediate position temporarily to permit pressure relief. A method of operating such a valve is also provided.
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FIELD OF THE INVENTION
The invention relates to instant scratch-off lottery games in general, and to means for preventing fraudulent alteration of the ticket.
BACKGROUND OF THE INVENTION
Instant scratch-off lottery tickets are being increasingly sold around the world.
Instant scratch-off lottery tickets contain hidden preprinted winning and losing game data which distinguish this form of lottery from the various other forms in which winning numbers are drawn some time after the sale of the ticket (conventional state lottery).
This scratch-off lottery utilizes a ticket, card, or other paper imprinted with indicia such as information relating to certain numbers, symbols, words and the like which indicate whether the bearer has won a prize. Such tickets must obscure the win-indicating information from observation by both the ticket distributor and the ticket purchaser as well until after the ticket has been sold. In this way, neither the ticket distributor nor the purchaser can determine which of a large number of tickets contain the win-indicating information.
After the ticket is purchased, the purchaser removes the material which obscures the information imprinted thereon. Once this coating is removed, the purchaser will know if he holds a winning ticket.
The games of the instant lotteries are generally of five main types:
1—Match three amounts or symbols and win that amount.
2—Match any of your preprinted numbers to another set of preprinted numbers and win a predetermined amount.
3—Bingo-type game
4—Compare your preprinted numbers or playing cards to a preprinted number(s) or playing cards. You win if you get higher numbers, etc.
5—You win if you have a preprinted winning symbol in your card.
All of the above categories of games and all the other currently available instant lottery games have a predetermined number of winning tickets. The tickets that have the winning indicia are sold randomly among the other tickets. The purchaser has no role in making the ticket he buys a winning one, nor has he the choice of entering his lucky numbers as he does in purchasing the conventional lottery ticket.
Players feel more satisfaction if they can choose their own numbers compared to having a ticket with preprinted winning indicia.
The current invention provides the combined advantages of the conventional lottery by allowing the purchaser to enter his chosen number and the advantage of the instant scratch-off lottery tickets by enabling the purchaser to immediately learn if the ticket is a winner or loser.
It is, therefore, a prime object of the current invention to provide a novel type of instant lottery scratch-off game in which any ticket could be a winning one if the player entered the correct numbers printed on that particular ticket.
It is another object of the present invention to provide endless new varieties of games where only the player has a major input and contribution to make the ticket a winning one.
It is another object of this invention to provide the player with prior knowledge of the amount of the prize and the probability of winning for each particular game.
It is another object of the current invention to create more trust and confidence in the lottery agency by making the player choose his own numbers.
It is another object of the current invention to provide a method for defeating any technique for nondestructive premature reading of the winning number printed on the card by providing a security bar code over-printed on the scratch-off material which covers the boxes which correspond to each number.
The security bar codes will enable the ticket distributor to transfer the information to a central computer of the lottery agency to approve or disapprove the payment of the prizes of the winning tickets.
In view of the above shortcomings of the instant lottery tickets, there is a need in the lottery business for new types of games which combine the advantages of traditional lottery games by allowing players to choose their own numbers and the advantage of the instant scratch-off ticket by allowing immediate learning if the ticket is a winner or loser.
SUMMARY OF THE INVENTION
The current invention relates to the structure of a game card of the instant scratch-off type of lotteries.
The current invention provides the combined advantages of the conventional lottery which allows the player to choose his own number to determine his chance of winning, and the advantage of the instant scratch-off lottery tickets by enabling the player to immediately learn if the ticket is a winning or a losing one.
It is another object of the invention to provide a method to ensure whether or not the ticket is invalidated by revealing more data than the player is allowed. This is achieved by a bar code, readable to a scanner, covering each box representing the number of the set of numbers printed on the card.
The current invention provides a plurality of games allowing the player to pick his own number, which varies with each particular game, which could be pick 1, 2, 3, 4, 5, 6, or more numbers from a set of numbers. Each number of this set is represented by a box covered by the scratch-off material which is over-printed with an appropriate bar code readable to a scanner (such scanners are already widely used in stores).
The winning number for each ticket is chosen randomly by a central processor of the lottery agency and stored in its data associated with the serial number of the ticket which is also printed on the card as a scanner readable bar code. The winning numbers are marked by symbols inside the corresponding boxes and are hidden by the scratch-off material and the over-printed security bar code. The winning numbers are unique for each card.
The player is instructed to remove only the material covering the boxes which corresponds to the numbers chosen. If the player reveals more boxes than allowed for that particular game, the card is invalidated and the player loses even if he reveals the correct numbers.
For example, if the player is playing the Pick 3 games, he is instructed to choose only three numbers of a set of numbers printed on the card. He has to remove only the scratch-off material covering the boxes (or fields) of his three selected numbers.
The ticket distributors are provided with scanners (not part of the invention--already available in the market), that can read the serial number of the ticket and the security bar code for each box number to verify that winning numbers are revealed and that only certain numbers of the fields are revealed and the covering security bar codes of the rest of the fields are not violated. The information thus obtained is transferred to the central processor of the lottery agency to approve or disapprove the payment of the prizes.
In another embodiment of the invention; the scanner-readable code is placed in all the fields, including the winning fields. The scratch-off material covers all the fields and codes, along with the winning symbols. The scanner may verify that the proper number of fields have been revealed and that the ticket is valid by scanning the codes that are revealed. A winning ticket would be determined as above by the symbols in the revealed fields.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rough drawing of a ticket for Pick 6 numbers showing the numbers and their corresponding boxes covered with a security bar code.
FIG. 2 is a rough drawing of a ticket for Pick 6 numbers, with a player having entered six numbers, 3, 8, 13, 28, 43, and 47. The player matched five numbers of the six.
FIGS. 3, 4 and 5 show examples of different types of playing Pick 3 numbers with different probabilities of winning, and hence different prizes.
FIG. 6 is a rough drawing of a cross-section of the lottery ticket showing the security bar codes 3 over-printed on the scratch-off material 9.
FIG. 7 is a drawing of another embodiment of a ticket in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The current invention relates to the structure of a game card of the instant scratch-off type of lotteries.
In FIG. 1, an example of the proposed games is illustrated. The manufacturing of these kinds of tickets is well known to those of ordinary skill in the art, and is beyond the scope of this invention.
The card needs to be made of multi-layered card protected against see-through, difficult to forge, in which the hidden data are printed with an ink having no or minimal radio opacity, such as described by Silverschotz et al., in U.S. Pat. No. 5,542,710, and Meloni et al. in U.S. Pat. No. 4,787,950, and by Hansell, U.S. Pat. No. 5,407,535, and by Goldman in U.S. Pat. No. 4,191,376.
The card is overprinted with a group of numbers 10. The group may consist of any amount of numbers, which varies with the type of game played and the rules set by the lottery agency.
Each number of this group is represented by a small box 4 or area, or a game field of any other shape, like a circle, heart, etc. The box is covered with a printed security bar code 3 representing the number. This security code is readable to an ordinary scanner available in almost every store. It should be noted that this security code need not be of the bar code type; any symbol readable to scanners can be used.
In FIG. 6, a sectional view of the card is illustrated showing the security code 3 overprinted on the scratch-off material 9 which is coating the other layers 2 of the card 1 .
The card has a field 5 for the serial number of the card, as well as its scanner readable bar code 6 . The bar code is printed on the card itself and may or may not be coated with scratch-off material for covering the serial number and its readable bar code.
The serial number will indicate the predetermined numbers of the field the player is allowed to reveal its content; example 03-000 0000 00000 indicates that the card is a pick 3 fields only, and 05-000 00000 indicates that the card is a pick 5 fields only.
The rest of the serial number is the number of the ticket associated with the predetermined winning numbers chosen randomly by the central processor of the lottery agency.
Instructions on the rules of the game are overprinted with the amount of the prizes. For example, in FIG. 1, the player is instructed to pick only six numbers by scratching off the material covering the corresponding six fields to reveal the contents of those fields, from a group of the fields 10 . If the player reveals more than six fields, the ticket will be invalidated. This can be immediately recognized by the scanners reading the ticket.
Each ticket has winning numbers chosen randomly by a central computer processor in the lottery agency and the winning numbers are stored with their corresponding serial number in the computer. The winning numbers of selectable game fields (e.g., 1-6 fields) are associated with the serial number of each ticket.
To verify a winning ticket, the computer should compare the numbers whose security code is erased by removal of the scratch-off with the serial number of the ticket and that only a certain number of fields as instructed are chosen by the player (like six fields in the Pick 6 game) by verifying the integrity of the security codes over the rest of the fields which correspond to the numbers.
FIG. 2 shows that by scratching off the security code of the numbers chosen by a player he will immediately learn if he chooses the fields with winning numbers or symbols or not.
Winning numbers are indicated by hidden symbol 7 in the boxes 4 of the numbers. The symbol can be a letter, another number, a word, a certain color, or any other mark or indicator determined by the lottery agency.
It is shown in FIG. 2, as an example, the player has chosen fields numbers 3, 8, 13, 28, 43, and 47. The winning numbers were 3, 8, 28, 35 (which the player did not choose and which is still hidden by the security code), 43, and 47. As seen, the field of number 13 does not have a winning symbol and therefore is represented by either an empty field 8 or another symbol to indicate a non-winning number.
Prizes vary with each particular game and the probability of winning for each game.
In general, the probability of winning for any lottery game is the product of the probability of winning of each one attempt multiplied by the number of attempts. Therefore, in the conventional lottery of Ohio Super Lotto, where players have to choose six numbers from 1 to 47, the probability for each one ticket is 1/10,737,573. If the volume of ticket sales exceeds 10 million tickets, the probability of a winner approaches % 100.
For the same game (Pick 6 from 1 to 47) on the current invention, the probability for each player remains the same 1/10,737,573, but the probability of a winner remains 1/10,373,573 because each winning number on a particular card is always played only once.
This will give the lottery agency tremendous benefits. The purchaser, on the other hand, as an individual, is not affected. His chance of winning remains the same whether he played the same game on the conventional lottery or the scratch-off type, but he has the advantage of learning immediately whether he is a winner or not.
By reducing the probability of having a winner, the lottery agency has a great benefit and it allows them to increase the chances and the amount to be won by the player, which generally improves the chance of the player to be a winner, compared to the conventional lottery.
For example, in the Ohio Super Lotto (Pick 6 from 1 to 47), matching four numbers out of six, with a probability of 1/11891, wins only $70-120. With the current invention for the same game, the lottery agency can increase the prize up to $10,000, or can increase the chance of winning by awarding match 3 or 2 numbers out of the six.
Overall, the current invention increases the chances of winning and benefits for the players as well as the lottery agency.
FIGS. 3, 4 , and 5 show some of the varieties of games with the prizes varying with changing the set of numbers the player has to choose from.
FIG. 7 discloses a lottery ticket 21 which has a plurality of game fields 30 , which may or may not be associated with one or more numerical or other symbols 31 . Lottery card 21 also includes a field 25 for the serial number of the card and the scanner-readable code 26 utilized to interpret the card's authenticity as well as whether the card is a winning card, a losing card, or an invalidated card. The winning game fields 30 are indicated by a hidden symbol 27 within the game field 30 . The object of a person playing the game represented by the lottery card 21 is to find each of the winning symbols 27 that are hidden in the game fields 30 by scratch-off material 29 . As discussed above, scratch-off material is scraped from a particular game field to reveal whether that game field contains a hidden winning symbol 27 or whether the game field is a losing game field. The number of hidden winning symbols 27 on the card 21 is determined by the type of game associated with the card. For example, four, five or six winning symbols might have to be revealed, although a greater or lesser number might also be utilized for the game of card 21 . A person playing the game can only scratch off a designated number of symbols. In FIG. 7, the game is a pick six type of game, and thus, six fields are revealed by scratching off material 29 to reveal the contents of those fields. If the player is chosen correctly and has scratched off the material 29 to reveal six wining symbols 27 , then that person is a winner and the card 21 represents a winning card. In FIG. 7, the fields represented by numerals 17 , 23 , 34 , and 44 all show winning symbols 27 therein and, thus, would be considered winning game fields 30 . However, the scratched-off fields indicated by numbers 4 and 25 do not contain a winning symbol 27 and, thus, would be considered losing fields. While the ticket 21 would then not be considered a winning ticket for the pick six contest, there may be other levels of contest such as getting four or five fields within the pick six game. That is, as discussed above, related games might also be associated with card 21 , and thus, four winning fields with winning symbols 27 could indicate a winning card at a particular level. Usually, the money for matching or uncovering four or five winning fields within a pick six card 21 will be less than the money prize for getting all six of the fields correct.
In accordance with one aspect of the present invention, as discussed above, a card such as card 21 shown in FIG. 7 might be invalidated if scratch-off material 29 from more than six fields 30 is removed. That is, if the scratch-off material from seven, eight, or a greater number of fields is removed, the ticket 21 would be invalid. Of course, a lesser number of fields than six might also be scratched off and not necessarily invalidate the card. For example, if the person is happy with finding four or five of the hidden winning symbols 27 , they may not scratch-off a sixth field. It seems unlikely that such a situation would occur, but it is possible.
For the purposes of validating a winning ticket 21 or invalidating the ticket, beneath the scratch-off material for any given game field 30 is a scanner-readable code 23 , such as a bar code. The scanner would verify that only six or less bar codes are revealed by the game fields 30 from which the scratch-off material has been removed. In the embodiment of the invention described hereinabove, the scanner-readable code or bar code was printed on the scratch-off material, and thus, a scanner would detect the absence of greater than six codes to invalidate a ticket or equal to or less than six fields to indicate a valid ticket regardless of whether the ticket is a winning ticket or not. Of course, the maximum number of fields from which the scratch-off material may be removed will depend upon the type of game indicated by the card 21 . To that end, the scanner-readable code is printed within the fields 30 . For a winning game field, the scanner-readable code 23 is printed along with a winning symbol 27 as shown in the fields 17 , 23 , 34 and 44 in the example of FIG. 7 .
To verify a winning ticket, a device such as a computer, would verify that only a certain number of fields have been chosen by checking the number of exposed codes 23 . It should be noted that while FIG. 7 shows the winning symbols 27 over the codes 23 for illustration, the codes 23 are still readable. If neccessary, the winning symbols 27 may be placed adjacent to the codes so as not to interfere with the reading of the codes.
While this invention has been described as having a preferred design, it is understood that it is capable of further modification, uses and/or adaptations of the invention following in general the principles of the invention and including such departure from the present disclosure as comes within the known or customary practice in the art to which the invention pertains and as may be applied to the central feature hereinbefore set forth, and fall within the scope of the invention and the limits of the appended claims.
An example of this modification is the association of the fields with letters or symbols or even no association with anything, just presenting fields as fields for selection by a player.
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A tamper resistant lottery ticket for preventing payoff of invalid tickets comprises a ticket body and a plurality of game files which are choosable by a lottery player. At least one winning symbol for the ticket is positioned in a game field, and a scratch-off material covers the game fields to hide contents of the game fields and therefore hide the at least one winning symbol. The scratch-off material is removable by a lottery player to reveal the contents of a game field when the game field is chosen. A readable security code is printed in each of the game fields, and the security code is covered by a scratch-off material with the at least one winning symbol and is revealed when the content of the game field is chosen and the scratch-off material is removed. The security codes of the ticket may be read to ensure that the proper number of game field contents are revealed and the lottery ticket is valid.
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FIELD OF THE INVENTION
[0001] The present invention relates to a pharmaceutical composition having pharmacological activity for the treatment and prevention of kidney diseases. More specifically, the present invention relates to a pharmaceutical composition for the treatment and prevention of kidney diseases, including (a) a therapeutically effective amount of a certain naphthoquinone-based compound or a pharmaceutically acceptable salt, prodrug, solvate or isomer thereof as an active ingredient, and (b) a pharmaceutically acceptable carrier, diluent or excipient or any combination thereof.
BACKGROUND OF THE INVENTION
[0002] The kidney is an important organ responsible for homeostasis of living organisms, and carries out the formation and excretion of urine through glomerular filtration and renal tubular reabsorption and secretion processes, whereby it is involved in various physiological functions, e.g. control of body fluid, electrolyte and acidity, excretion of various wastes including metabolic wastes, toxins and drug substances, control of blood pressure, and other metabolic and endocrine functions.
[0003] Impairment of renal function results in enlargement of the kidney and related structures, renal atrophy, changes of body fluid levels, electrolyte imbalance, metabolic acidosis, impaired gas exchange, compromised anti-infective activity, accumulation of potential uremic toxins, and the like. Some substances are reported to promote the renal function, for example, dopamine, theophylline, and ANP as an endogenous activator.
[0004] Kidney diseases refers to medical conditions that result from renal functional decline and are therefore accompanied by internal accumulation of wastes or excretes in conjunction with water excess conditions of the body due to loss of ability to remove and control hazardous chemicals and moisture. The term “kidney disease” in a broad sense includes all the chronic renal diseases, and in a narrow sense, it refers to diseases whose pathological causes remain unclear and which are manifested with constitutional changes and deterioration of glomerular filtration function.
[0005] The kidney diseases can be categorized into hereditary, congenital and acquired types.
[0006] Hereditary diseases show clinical symptoms generally in the juvenile period and include, most frequently, polycystic kidney disease (PKD) and rarely, Alport's syndrome, hereditary nephritis, etc. Congenital diseases include urogenital malformation, which may cause urinary tract obstruction or urinary tract infection to destroy the kidney tissue, finally resulting in renal failure. Acquired diseases include various kinds of nephritis, most frequently glomerular nephritis. Kidney diseases may also be caused by systemic diseases such as diabetes, systemic lupus erythematosus (SLE), hypertension, etc. Other pathogenic factors of the kidney diseases may include urolithiasis and drugs such as herbal medicines, analgesics, insecticides, and the like.
[0007] In the past, the incidence of kidney diseases was primarily due to chronic glomerulitis. At present, diabetic chronic renal failure is dominant due to increased prevalence of diabetes, although therapeutic regimens against glomerulitis were improved. In addition, other medical conditions, such as lupus, hypertension, renal tuberculosis, renal calculus, polycystic kidney disease (PKD) and chronic pyelonephritis, may also contribute to the pathogenesis of kidney diseases. However, there are many cases whose pathogenic causes are not understood because diseases of interest are identified too late after the kidney has been almost functionally disabled.
[0008] Acute renal failure (ARF) is a rapid loss of renal function to the point where it is not possible to maintain normal levels of nitrogenous waste products (for example, blood urea nitrogen (BUN) and creatinine) in the body.
[0009] Chronic renal failure (CRF) is a gradual and progressive loss of renal function over a period of months or years. Chronic renal failure is derived from all kinds of diseases due to progressive loss of renal function and broadly ranges from mild renal dysfunction to severe renal failure. Further progress of the concerned disease leads to end-stage renal disease (ESRD). Due to no subjective symptoms and very slow progress of the disease at the early stage of chronic renal failure, noticeable symptoms are not expressed even when the renal function is deteriorated to a 1/10 level of normal renal function. Diabetes and hypertension are known to be primary pathogenic causes of CRF and ESRD (Jacobsen, 2005; Nordfors et al., 2005).
[0010] Subacute renal failure (SRF) refers to a moderate condition between CRF and ARF. The subacute renal failure is manifested with clinical characteristics of ARF as well as clinical characteristics of CRF (Daeschner and Singer, 1973; Mills et al., 1981; Bal et al., 2000).
[0011] Diabetic nephropathy, kidney damage caused by diabetes, most often involves thickening and hardening (sclerosis) of the internal kidney structures, particularly the glomerulus (kidney membrane). Kimmelstiel-Wilson disease is the unique microscopic characteristic of diabetic nephropathy in which sclerosis of the glomeruli is accompanied by nodular deposits of hyaline.
[0012] The glomeruli are the sites where blood is filtered and urine is formed. They act as a selective membrane, allowing some substances to be excreted in the urine and other substances to remain in the body. As diabetic nephropathy progresses, increasing numbers of glomeruli are destroyed, resulting in impaired kidney functioning. Filtration slows and protein, namely albumin may leak into the urine. Albumin may appear in the urine for 5 to 10 years before other symptoms develop.
[0013] Diabetic nephropathy may eventually lead to the nephrotic syndrome (a group of symptoms characterized by excessive loss of protein in the urine) and chronic renal failure. The disorder continues to progress, with end-stage renal disease developing, usually within 2 to 6 years after the appearance of renal insufficiency with proteinuria.
[0014] The mechanism that causes diabetic nephropathy is unknown. It may be caused by inappropriate incorporation of glucose molecules into the structures of the basement membrane and the tissues of the glomerulus. Hyperfiltration associated with high blood sugar levels may be an additional mechanism of disease development.
[0015] The diabetic nephropathy is the most common cause of chronic renal failure and end stage renal disease in the United States. About 40% of people with insulin-dependent diabetes will eventually develop end-stage renal disease. 80% of patients with diabetic nephropathy as a result of insulin-dependent diabetes mellitus (IDDM) have had this diabetes for 18 or more years. At least 20% of patients with non-insulin-dependent diabetes mellitus (NIDDM) will develop diabetic nephropathy, but the time course of development of the disorder is much more variable than in IDDM. The risk is related to the control of the blood-glucose levels. Risk is higher if glucose is poorly controlled than if the glucose level is well controlled.
[0016] Diabetic nephropathy is generally accompanied by other diabetic complications including hypertension, retinopathy, and vascular (blood vessel) changes, although these may not be obvious during the early stages of nephropathy. Nephropathy may be present for many years before nephrotic syndrome or chronic renal failure develops. Nephropathy is often diagnosed when routine urinalysis shows protein in the urine.
[0017] Current treatments for diabetic nephropathy include administration of angiotensin converting enzyme inhibitors (ACE Inhibitors), such as captopril (trade name Capoten) during the more advanced stages of the disease. Currently there is no treatment in the earlier stages of the disease since ACE inhibitors may not be effective when the disease is symptom-free (i.e., when the patient only shows proteinuria).
SUMMARY OF THE INVENTION
[0018] Therefore, the present invention has been made to solve the above problems and other technical problems that have yet to be resolved.
[0019] It is therefore an object of the invention to provide a pharmaceutical composition containing (a) a therapeutically effective amount of a certain naphthoquinone-based compound having therapeutic and prophylactic effects on kidney diseases, as an active ingredient.
[0020] In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of a pharmaceutical composition for the treatment and prevention of kidney diseases, comprising: (a) a therapeutically effective amount of one or more selected from compounds represented by Formulae 1 and 2 below: or a pharmaceutically acceptable salt, prodrug, solvate or isomer thereof; and
[0021] (b) a pharmaceutically acceptable carrier, diluent or excipient or any combination thereof
[0000]
[0000] wherein:
[0022] R 1 and R 2 are each independently hydrogen, halogen, hydroxyl, or C 1 -C 6 lower alkyl or alkoxy, or R 1 and R 2 may be taken together to form a substituted or unsubstituted cyclic structure which may be saturated or partially or completely unsaturated;
[0023] R 3 , R 4 , R 5 , R 6 , R 7 and R 8 are each independently hydrogen, hydroxyl, C 1 -C 20 alkyl, alkene or alkoxy, or C 4 -C 20 cycloalkyl, heterocycloalkyl, aryl or heteroaryl, or two of R 3 to R 8 may be taken together to form a cyclic structure which may be saturated or partially or completely unsaturated;
[0024] X is selected from the group consisting of C(R)(R′), N(R″) wherein R, R′ and R″ are each independently hydrogen or C 1 -C 6 lower alkyl, O and S, preferably O or S, and more preferably O;
[0025] Y is C, S or N, with proviso that R 7 and R 8 are absent when Y is S, and R 7 is hydrogen or C 1 -C 6 lower alkyl and R 8 is absent when Y is N; and
[0026] n is 0 or 1, with proviso that when n is 0, carbon atoms adjacent to n form a cyclic structure via a direct bond.
[0027] From the experiments conducted to investigate therapeutic effects of a pharmaceutical composition in accordance with the present invention on kidney diseases, the inventors of the present invention have discovered that the pharmaceutical composition of the present invention significantly lowers a serum creatinine level and a blood urea nitrogen (BUN) level and decreases excretion of proteinuria in acute renal failure- and diabetic nephropathy-induced animal models, thereby confirming beneficial therapeutic effects on kidney diseases.
[0028] Accordingly, the pharmaceutical composition in accordance with the present invention can be therapeutically or prophylactically used for various kinds of kidney diseases. In the context of the present invention, the term “kidney disease” is a broad concept encompassing all kinds of renal diseases and disorders and may include, for example, glomerulonephritis, diabetic nephropathy, chronic renal failure, acute renal failure, subacute renal failure, malignant nephrosclerosis, thrombotic microangiopathy syndromes, transplant rejection, glomerulopathies, renal hypertrophy, renal hyperplasia, proteinuria, contrast medium-induced nephropathy, toxin-induced renal injury, oxygen free radical-mediated nephropathy and nephritis. Preferred is acute renal failure or diabetic nephropathy.
[0029] As used the present disclosure, the term “pharmaceutically acceptable salt” means a formulation of a compound that does not cause significant irritation to an organism to which it is administered and does not abrogate the biological activity and properties of the compound. Examples of the pharmaceutical salt may include acid addition salts of the compound with acids capable of forming a non-toxic acid addition salt containing pharmaceutically acceptable anions, for example, inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, hydrobromic acid and hydroiodic acid; organic carbonic acids such as tartaric acid, formic acid, citric acid, acetic acid, trichloroacetic acid, trifluoroacetic acid, gluconic acid, benzoic acid, lactic acid, fumaric acid, maleic acid and salicylic acid; or sulfonic acids such as methanesulfonic acid, ethanesulfonic acid, benzenesulfonic acid and p-toluenesulfonic acid. Specifically, examples of pharmaceutically acceptable carboxylic acid salts include salts with alkali metals or alkaline earth metals such as lithium, sodium, potassium, calcium and magnesium, salts with amino acids such as arginine, lysine and guanidine, salts with organic bases such as dicyclohexylamine, N-methyl-D-glucamine, tris(hydroxymethyl)methylamine, diethanolamine, choline and triethylamine. The compounds in accordance with the present invention may be converted into salts thereof, by conventional methods well-known in the art.
[0030] As used herein, the term “prodrug” means an agent that is converted into the parent drug in vivo. Prodrugs are often useful because, in some situations, they may be easier to administer than the parent drug. They may, for instance, be bioavailable by oral administration, whereas the parent may be not. The prodrugs may also have improved solubility in pharmaceutical compositions over the parent drug. An example of a prodrug, without limitation, would be a compound of the present invention which is administered as an ester (the “prodrug”) to facilitate transport across a cell membrane where water-solubility is detrimental to mobility, but which then is metabolically hydrolyzed to the carboxylic acid, the active entity, once inside the cell where water solubility is beneficial. A further example of the prodrug might be a short peptide (polyamino acid) bonded to an acidic group, where the peptide is metabolized to reveal the active moiety.
[0031] As an example of such prodrug, the pharmaceutical compounds in accordance with the present invention can include a prodrug represented by Formula 1a below as an active material:
[0000]
[0000] wherein,
[0032] R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , X and n are as defined in Formula 1.
[0033] R 9 and R 10 are each independently —SO 3 − Na + or substituent represented by Formula A below or a salt thereof,
[0000]
[0000] wherein,
[0034] R 11 and R 12 are each independently hydrogen or substituted or unsubstituted C 1 -C 20 linear alkyl or C 1 -C 20 branched alkyl,
[0000] R 13 is selected from the group consisting of substituents i) to viii) below:
i) hydrogen; ii) substituted or unsubstituted C 1 -C 10 linear alkyl or C 1 -C 20 branched alkyl; iii) substituted or unsubstituted amine; iv) substituted or unsubstituted C 3 -C 10 cycloalkyl or C 3 -C 10 heterocycloalkyl; v) substituted or unsubstituted C 4 -C 10 aryl or C 4 -C 10 heteroaryl; vi) —(CRR′—NR″CO) 1 —R 14 , wherein R, R′ and R″ are each independently hydrogen or substituted or unsubstituted C 1 -C 20 linear alkyl or C 1 -C 20 branched alkyl, R 14 is selected from the group consisting of hydrogen, substituted or unsubstituted amine, cycloalkyl, heterocycloalkyl, aryl and heteroaryl, 1 is selected from the 1˜5; vii) substituted or unsubstituted carboxyl; viii) —OSO 3 —Na + ;
[0043] k is selected from the 0˜20, with proviso that when k is 0, R 11 and R 12 are not anything, and R 13 is directly bond to a carbonyl group.
[0044] As used herein, the term “solvate” means a compound of the present invention or a salt thereof, which further includes a stoichiometric or non-stoichiometric amount of a solvent bound thereto by non-covalent intermolecular forces. Preferred solvents are volatile, non-toxic, and/or acceptable for administration to humans. Where the solvent is water, the solvate refers to a hydrate.
[0045] As used herein, the term “isomer” means a compound of the present invention or a salt thereof that has the same chemical formula or molecular formula but is optically or sterically different therefrom. Unless otherwise specified, the term “compound of Formula 1 or 2” is intended to encompass a compound per se, and a pharmaceutically acceptable salt, prodrug, solvate and isomer thereof.
[0046] As used herein, the term “alkyl” refers to an aliphatic hydrocarbon group. The alkyl moiety may be a “saturated alkyl” group, which means that it does not contain any alkene or alkyne moieties. Alternatively, the alkyl moiety may also be an “unsaturated alkyl” moiety, which means that it contains at least one alkene or alkyne moiety. The term “alkene” moiety refers to a group in which at least two carbon atoms form at least one carbon-carbon double bond, and an “alkyne” moiety refers to a group in which at least two carbon atoms form at least one carbon-carbon triple bond. The alkyl moiety, regardless of whether it is substituted or unsubstituted, may be branched, linear or cyclic.
[0047] As used herein, the term “heterocycloalkyl” means a carbocyclic group in which one or more ring carbon atoms are substituted with oxygen, nitrogen or sulfur and which includes, for example, but is not limited to furan, thiophene, pyrrole, pyrroline, pyrrolidine, oxazole, thiazole, imidazole, imidazoline, imidazolidine, pyrazole, pyrazoline, pyrazolidine, isothiazole, triazole, thiadiazole, pyran, pyridine, piperidine, morpholine, thiomorpholine, pyridazine, pyrimidine, pyrazine, piperazine and triazine.
[0048] As used herein, the term “aryl” refers to an aromatic substituent group which has at least one ring having a conjugated pi (π) electron system and includes both carbocyclic aryl (for example, phenyl) and heterocyclic aryl(for example, pyridine) groups. This term includes monocyclic or fused-ring polycyclic (i.e., rings which share adjacent pairs of carbon atoms) groups.
[0049] As used herein, the term “heteroaryl” refers to an aromatic group that contains at least one heterocyclic ring.
[0050] Examples of aryl or heteroaryl include, but are not limited to, phenyl, furan, pyran, pyridyl, pyrimidyl and triazyl.
[0051] R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 and R 8 in Formula 1 or 2 in accordance with the present invention may be optionally substituted. When substituted, the substituent group(s) is(are) one or more group(s) individually and independently selected from cycloalkyl, aryl, heteroaryl, heteroalicyclic, hydroxy, alkoxy, aryloxy, mercapto, alkylthio, arylthio, cyano, halogen, carbonyl, thiocarbonyl, O-carbamyl, N carbamyl, O-thiocarbamyl, N-thiocarbamyl, C-amido, N-amido, S-sulfonamido, N-sulfonamido, C-carboxy, O-carboxy, isocyanato, thiocyanato, isothiocyanato, nitro, silyl, trihalomethanesulfonyl, and amino including mono and di substituted amino, and protected derivatives thereof. Further, substituents of R 11 , R 11 and R 13 in the Formula 1a may be also substituted as defined in above, and when substituted, they can be substituted as the substituents mentioned above.
[0052] Among compounds of Formula 1, preferred are compounds of Formulas 3 and 4 below.
[0053] Compounds of Formula 3 are compounds wherein n is 0 and adjacent carbon atoms form a cyclic structure (furan ring) via a direct bond therebetween and are often referred to as “furan compounds” or “furano-o-naphthoquinone derivatives” hereinafter.
[0000]
[0054] Compounds of Formula 4 are compounds wherein n is 1 and are often referred to as “pyran compounds” or “pyrano-o-naphthoquinone” hereinafter.
[0000]
[0055] In Formula 1, each of R 1 and R 2 is particularly preferably hydrogen.
[0056] Among the furan compounds of Formula 3, particularly preferred are compounds of Formula 3a wherein R 1 , R 2 and R 4 are hydrogen, or compounds of Formula 3b wherein R 1 , R 2 and R 6 are hydrogen.
[0000]
[0057] Further, among the pyran compounds of Formula 4, particularly preferred is compounds of Formula 4a wherein R 1 , R 2 , R 5 , R 6 , R 7 and R 8 are hydrogen or compounds of Formula 4b or 4c wherein R 1 and R 2 are taken together to form a cyclic structure which is substituted or unsubstituted.
[0000]
[0058] Among compounds of Formula 2, preferred without limitation, are compounds of Formulas 2a and 2b below.
[0059] Compounds of Formula 2a are compounds wherein n is 0 and adjacent carbon atoms form a cyclic structure via a direct bond therebetween and Y is C.
[0000]
[0060] Compounds of Formula 2b are compounds wherein n is 1 and Y is C.
[0000]
[0061] In the Formula 2a or 2b, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and X are as defined in Formula 2.
[0062] Effective substance which exerts therapeutic effect on the treatment and/or prevention of prostate and/or testicle (seminal glands)-related diseases in the present invention is often referred to as “active ingredient” hereinafter.
Preparation of Active Ingredient
[0063] In the pharmaceutical composition in accordance with the present invention, compounds of Formula 1 or Formula 2, as will be illustrated hereinafter, can be prepared by conventional methods known in the art and/or various processes which are based upon the general technologies and practices in the organic chemistry synthesis field. The preparation processes described below are only exemplary ones and other processes can also be employed. As such, the scope of the instant invention is not limited to the following processes.
[0064] In general, tricyclic naphthoquinone (pyrano-o-naphthoquinone and furano-o-naphthoquinone) derivatives can be synthesized by two methods mainly. One is to derive cyclization reaction using 3-allyl-2-hydroxy-1,4-naphthoquinone in acid catalyst condition, as the following β-lapachone synthesis scheme.
[0000]
[0065] That is, 3-allyloxy-1,4-phenanthrenequinone can be obtained by deriving Diels-Alder reaction between 2-allyloxy-1,4-benzoquinone and styrene or 1-vinylcyclohexane derivatives and dehydrating the resulting intermediates using oxygen present in the air or oxidants such as NaIO 4 and DDQ. By further re-heating the above compound, 2-allyl-3-hydroxy-1,4-phenanthrenequinone of Lapachole form can be synthesized via Claisen rearrangement.
[0000]
[0066] When the thus obtained 2-allyl-3-hydroxy-1,4-phenanthrenequinone is ultimately subjected to cyclization in an acid catalyst condition, various 3,4-phenanthrenequinone-based or 5,6,7,8-tetrahydro-3,4-phenanthrenequinone-based compounds can be synthesized. In this case, 5 or 6-cyclic cyclization occurs depending on the types of substituents (R 21 , R 22 , R 23 in the above formula) represented in the above formula, and also they are converted to the corresponding, adequate substituents (R 11 , R 12 , R 13 , R 14 , R 15 , R 16 in the below formula).
[0000]
[0067] Further, 3-allyloxy-1,4-phenanthrenequinone is hydrolyzed to 3-oxy-1,4-phenanthrenequinone, in the condition of acid (H + ) or alkali (OH − ) catalyst, which is then reacted with various allyl halides to synthesize 2-allyl-3-hydroxy-1,4-phenanthrenequinone by C-alkylation. The thus obtained 2-allyl-3-hydroxy-1,4-phenanthrenequinone derivatives are subject to cyclization in the condition of acid catalyst to synthesize various 3,4-phenanthrenequinone-based or 5,6,7,8-tetrahydro-3,4-naphthoquinone-based compounds. In this case, 5 or 6-cyclic cyclization occurs depending on the types of substituents (R 21 , R 22 , R 23 in the above formula) represented in the above formula, and also they are converted to the corresponding, adequate substituents (R 11 , R 12 , R 13 , R 14 , R 15 , R 16 in the below formula).
[0000]
[0068] However, compounds in which substituents R 11 and R 12 are simultaneously hydrogen cannot be obtained by acid-catalyzed cyclization. These derivatives are obtained on the basis of a method reported by J. K. Snyder et al (Tetrahedron Letters 28 (1987), 3427-3430), more specifically, by first obtaining furanobenzoquinone introduced furan ring by cyclization, and then obtaining tricyclic phenanthroquinone by cyclization with 1-vinylcyclohexene derivatives, followed by reduction via hydrogen-addition. The above synthesis process can be summarized as follows.
[0000]
[0069] Besides the above synthetic method, compounds according to present invention in which substituents R 11 and R 12 are simultaneously hydrogen can be synthesized by the following method.
[0070] Preparation method 1 is a synthesis of active ingredient by acid-catalyzed cyclization which may be summarized in the general chemical reaction scheme as follows.
[0000]
[0071] That is, when 2-hydroxy-1,4-naphthoquinone is reacted with various allylic bromides or equivalents thereof in the presence of a base, a C-alkylation product and an O-alkylation product are concurrently obtained. It is also possible to synthesize only either of two derivatives depending upon reaction conditions. Since O-alkylated derivative is converted into another type of C-alkylated derivative through Claisen Rearrangement by refluxing the O-alkylated derivative using a solvent such as toluene or xylene, it is possible to obtain various types of 3-substituted-2-hydroxy-1,4-naphthoquinone derivatives. The various types of C-alkylated derivatives thus obtained may be subjected to cyclization using sulfuric acid as a catalyst, thereby being capable of synthesizing pyrano-o-naphthoquinone or furano-o-naphthoquinone derivatives among the compounds.
[0072] Preparation method 2 is Diels-Alder reaction using 3-methylene-1,2,4-[3H]naphthalenetrione. As taught by V. Nair et al, Tetrahedron Lett. 42 (2001), 4549-4551, it is reported that a variety of pyrano-o-naphthoquinone derivatives can be relatively easily synthesized by subjecting 3-methylene-1,2,4-[3H]naphthalenetrione, produced upon heating 2-hydroxy-1,4-naphthoquinone and formaldehyde together, to Diels-Alder reaction with various olefin compounds. This method is advantageous in that various forms of pyrano-o-naphtho-quinone derivatives can be synthesized in a relatively simplified manner, as compared to induction of cyclization using sulfuric acid as a catalyst.
[0000]
[0073] Preparation method 3 is haloalkylation and cyclization by radical reaction. The same method used in synthesis of cryptotanshinone and 15,16-dihydro-tanshinone can also be conveniently employed for synthesis of furano-o-naphthoquinone derivatives. That is, as taught by A. C. Baillie et al (J. Chem. Soc. (C) 1968, 48-52), 2-haloethyl or 3-haloethyl radical chemical species, derived from 3-halopropanoic acid or 4-halobutanoic acid derivative, can be reacted with 2-hydroxy-1,4-naphthoquinone to thereby synthesize 3-(2-haloethyl or 3-halopropyl)-2-hydroxy-1,4-naphthoquinone, which is then subjected to cyclization under suitable acidic catalyst conditions to synthesize various pyrano-o-naphthoquinone or furano-o-naphthoquinone derivatives.
[0000]
[0074] Preparation method 4 is cyclization of 4,5-benzofurandione by Diels-Alder reaction. Another method used in synthesis of cryptotanshinone and 15,16-dihydro-tanshinone may be a method taught by J. K. Snyder et al (Tetrahedron Letters 28 (1987), 3427-3430). According to this method, furano-o-naphthoquinone derivatives can be synthesized by cycloaddition via Diels-Alder reaction between 4,5-benzofurandione derivatives and various diene derivatives.
[0000]
[0075] Based on the above-mentioned preparation methods, various derivatives may be synthesized using relevant synthesis methods, depending upon kinds of substituents.
[0076] Among compounds of according to the present invention, particularly preferred are in Table 1 below, but are not limited thereto.
[0000]
TABLE 1
Preparation
No.
Chemical structure
Formula
Molecular weight
method
1
C 15 H 14 O 3
242.27
Method 1
2
C 15 H 14 O 3
242.27
Method 1
3
C 15 H 14 O 3
242.27
Method 1
4
C 14 H 12 O 3
228.34
Method 1
5
C 13 H 10 O 3
214.22
Method 1
6
C 12 H 8 O 3
200.19
Method 2
7
C 19 H 14 O 3
290.31
Method 1
8
C 19 H 14 O 3
290.31
Method 1
9
C 15 H 12 O 3
240.25
Method 1
10
C 16 H 16 O 4
272.30
Method 1
11
C 15 H 12 O 3
240.25
Method 1
12
C 16 H 14 O 3
254.28
Method 2
13
C 18 H 18 O 3
282.33
Method 2
14
C 21 H 22 O 3
322.40
Method 2
15
C 21 H 22 O 3
322.40
Method 2
16
C 14 H 12 O 3
228.24
Method 1
17
C 14 H 12 O 3
228.24
Method 1
18
C 14 H 12 O 3
228.24
Method 1
19
C 14 H 12 O 3
228.24
Method 1
20
C 20 H 22 O 3
310.39
Method 1
21
C 15 H 13 ClO 3
276.71
Method 1
22
C 16 H 16 O 3
256.30
Method 1
23
C 17 H 18 O 5
302.32
Method 1
24
C 16 H 16 O 3
256.30
Method 1
25
C 17 H 18 O 3
270.32
Method 1
26
C 20 H 16 O 3
304.34
Method 1
27
C 18 H 18 O 3
282.33
Method 1
28
C 17 H 16 O 3
268.31
Method 1
29
C 13 H 8 O 3
212.20
Method 1
30
C 13 H 8 O 3
212.20
Method 4
31
C 14 H 10 O 3
226.23
Method 4
32
C 14 H 10 O 3
226.23
Method 4
33
C 15 H 14 O 2 S
258.34
Method 1
34
C 15 H 14 O 2 S
258.34
Method 1
35
C 13 H 10 O 2 S
230.28
Method 1
36
C 15 H 14 O 2 S
258.34
Method 2
37
C 19 H 14 O 2 S
306.38
Method 2
38
C 12 H 8 O 3 S
232.26
Method 3
39
C 13 H 10 O 3 S
246.28
Method 3
40
C 14 H 12 O 3 S
260.31
Method 3
41
C 15 H 14 O 3 S
274.34
Method 3
42
C 28 H 37 O 7 N
502.22
—
43
C 23 H 30 O 5 NCl
940.32
—
44
C 28 H 33 O 7 N 3
526.22
—
45
C 23 H 26 O 5 N 3 Cl
988.32
—
46
C 17 H 16 O 3
268.31
—
47
C 19 H 20 O 3
296.36
—
48
C 19 H 20 O 3
296.36
—
49
C 21 H 24 O 3
324.41
—
50
C 21 H 24 O 3
324.41
—
51
C 19 H 20 O 3
296.36
—
52
C 17 H 12 O 3
264.28
—
53
C 19 H 16 O 3
292.33
—
54
C 18 H 14 O 3
278.30
—
55
C 20 H 18 O 3
306.36
—
56
C 21 H 20 O 3
320.38
—
57
C 23 H 24 O 3
348.43
—
58
C 17 H 11 ClO 3
298.72
—
59
C 18 H 14 O 3
278.30
—
60
C 18 H 14 O 4
294.30
—
61
C 20 H 18 O 3
306.36
—
62
C 18 H 18 O 3
282.33
—
63
C 18 H 16 O 3
280.33
—
64
C 18 H 14 O 3
278.33
—
65
C 18 H 12 O 3
276.33
—
[0077] The term “pharmaceutical composition” as used herein means a mixture of the compound of Formula 1 or 2 with other chemical components, such as diluents or carriers. The pharmaceutical composition facilitates administration of the compound to an organism. Various techniques of administering a compound are known in the art and include, but are not limited to oral, injection, aerosol, parenteral and topical administrations. Pharmaceutical compositions can also be obtained by reacting compounds of interest with acids such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid, methanesulfonic acid, p-toluenesulfonic acid, salicylic acid and the like. The effective ingredients, therapeutically effective for the treatment and prevention of restenosis include all the compounds of Formula in the above, referring “active ingredient” hereafter.
[0078] The term “therapeutically effective amount” means an amount of an active ingredient that is effective to relieve or reduce to some extent one or more of the symptoms of the disease in need of treatment, or to retard initiation of clinical markers or symptoms of a disease in need of prevention, when the compound is administered. Thus, a therapeutically effective amount refers to an amount of the active ingredient which exhibit effects of (i) reversing the rate of progress of a disease; (ii) inhibiting to some extent further progress of the disease; and/or, (iii) relieving to some extent (or, preferably, eliminating) one or more symptoms associated with the disease. The therapeutically effective amount may be empirically determined by experimenting with the compounds concerned in known in vivo and in vitro model systems for a disease in need of treatment.
[0079] In the pharmaceutical composition in accordance with the present invention, compounds of Formula 1 or 2 as an active ingredient, as will be illustrated hereinafter, can be prepared by conventional methods known in the art and/or various processes which are based upon the general technologies and practices in the organic chemistry synthesis field.
[0080] The pharmaceutical composition of the present invention may be manufactured in a manner that is itself known, e.g., by means of conventional mixing, dissolving, granulating, dragee-making, levigating, emulsifying, encapsulating, entrapping or lyophilizing processes.
[0081] Therefore, pharmaceutical compositions for use in accordance with the present invention may be additionally comprised of a pharmaceutically acceptable carrier, a diluent or an excipient, or any combination thereof. That may be formulated in a conventional manner using one or more pharmaceutically acceptable carriers comprising excipients and auxiliaries which facilitate processing of the active compounds into preparations which can be used pharmaceutically. The pharmaceutical composition facilitates administration of the compound to an organism.
[0082] The term “carrier” means a chemical compound that facilitates the incorporation of a compound into cells or tissues. For example, dimethyl sulfoxide (DMSO) is a commonly utilized carrier as it facilitates the uptake of many organic compounds into the cells or tissues of an organism.
[0083] The term “diluent” defines chemical compounds diluted in water that will dissolve the compound of interest as well as stabilize the biologically active form of the compound. Salts dissolved in buffered solutions are utilized as diluents in the art. One commonly used buffer solution is phosphate buffered saline (PBS) because it mimics the ionic strength conditions of human body fluid. Since buffer salts can control the pH of a solution at low concentrations, a buffer diluent rarely modifies the biological activity of a compound.
[0084] The compounds described herein may be administered to a human patient per se, or in the form of pharmaceutical compositions in which they are mixed with other active ingredients, as in combination therapy, or suitable carriers or excipient(s). Proper formulation is dependent upon the route of administration chosen. Techniques for formulation and administration of the compounds may be found in “Remington's Pharmaceutical Sciences,” Mack Publishing Co., Easton, Pa., 18th edition, 1990.
[0085] Various techniques relating to pharmaceutical formulation for administering an active ingredient into the body are known in the art and include, but are not limited to oral, injection, aerosol, parenteral and topical administrations. If necessary, they can also be obtained by reacting compounds of interest with acids such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid, methanesulfonic acid, p-toluenesulfonic acid, salicylic acid and the like.
[0086] Pharmaceutical formulation may be carried out by conventional methods known in the art and, Preferably, the pharmaceutical formulation may be oral, external, transdermal, transmucosal and an injection formulation, and particularly preferred is oral formulation.
[0087] Meanwhile, for injection, the agents of the present invention may be formulated in aqueous solutions, preferably in physiologically compatible buffers such as Hanks's solution, Ringer's solution, or physiological saline. For transmucosal administration, penetrants appropriate to the barrier to be permeated are used in the formulation. Such penetrants are generally known in the art.
[0088] The pharmaceutical compounds in accordance with the present invention, may be particularly preferably an oral pharmaceutical composition which is prepared into an intestine-targeted formulation.
[0089] Generally, an oral pharmaceutical composition passes through the stomach upon oral administration, is largely absorbed by the small intestine and then diffused into all the tissues of the body, thereby exerting therapeutic effects on the target tissues.
[0090] In this connection, the oral pharmaceutical composition according to the present invention enhances bioabsorption and bioavailability of a compound of Formula 1 or Formula 2 active ingredient via intestine-targeted formulation of the active ingredient. More specifically, when the active ingredient in the pharmaceutical composition according to the present invention is primarily absorbed in the stomach, and upper parts of the small intestine, the active ingredient absorbed into the body directly undergoes liver metabolism which is then accompanied by substantial degradation of the active ingredient, so it is impossible to exert a desired level of therapeutic effects. On the other hand, it is expected that when the active ingredient is largely absorbed around and downstream of the lower small intestine, the absorbed active ingredient migrates via lymph vessels to the target tissues to thereby exert high therapeutic effects.
[0091] Further, as it is constructed in such a way that the pharmaceutical composition according to the present invention targets up to the colon which is a final destination of the digestion process, it is possible to increase the in vivo retention time of the drug and it is also possible to minimize decomposition of the drug which may take place due to the body metabolism upon administration of the drug into the body. As a result, it is possible to improve pharmacokinetic properties of the drug, to significantly lower a critical effective dose of the active ingredient necessary for the treatment of the disease, and to obtain desired therapeutic effects even with administration of a trace amount of the active ingredient. Further, in the oral pharmaceutical composition, it is also possible to minimize the absorption variation of the drug by reducing the between- and within-individual variation of the bioavailability which may result from intragastric pH changes and dietary uptake patterns.
[0092] Therefore, the intestine-targeted formulation according to the present invention is configured such that the active ingredient is largely absorbed in the small and large intestines, more preferably in the jejunum, and the ileum and colon corresponding to the lower small intestine, particularly preferably in the ileum or colon.
[0093] The intestine-targeted formulation may be designed by taking advantage of numerous physiological parameters of the digestive tract, through a variety of methods. In one preferred embodiment of the present invention, the intestine-targeted formulation may be prepared by (1) a formulation method based on a pH-sensitive polymer, (2) a formulation method based on a biodegradable polymer which is decomposable by an intestine-specific bacterial enzyme, (3) a formulation method based on a biodegradable matrix which is decomposable by an intestine-specific bacterial enzyme, or (4) a formulation method which allows release of a drug after a given lag time, and any combination thereof.
[0094] Specifically, the intestine-targeted formulation (1) using the pH-sensitive polymer is a drug delivery system which is based on pH changes of the digestive tract. The pH of the stomach is in a range of 1 to 3, whereas the pH of the small and large intestines has a value of 7 or higher, as compared to that of the stomach. Based on this fact, the pH-sensitive polymer may be used in order to ensure that the pharmaceutical composition reaches the lower intestinal parts without being affected by pH fluctuations of the digestive tract. Examples of the pH-sensitive polymer may include, but are not limited to, at least one selected from the group consisting of methacrylic acid-ethyl acrylate copolymer (Eudragit: Registered Trademark of Rohm Pharma GmbH), hydroxypropylmethyl cellulose phthalate (HPMCP) and a mixture thereof.
[0095] Preferably, the pH-sensitive polymer may be added by a coating process. For example, addition of the polymer may be carried out by mixing the polymer in a solvent to form an aqueous coating suspension, spraying the resulting coating suspension to form a film coating, and drying the film coating.
[0096] The intestine-targeted formulation (2) using the biodegradable polymer which is decomposable by the intestine-specific bacterial enzyme is based on the utilization of a degradative ability of a specific enzyme that can be produced by enteric bacteria. Examples of the specific enzyme may include azoreductase, bacterial hydrolase glycosidase, esterase, polysaccharidase, and the like.
[0097] When it is desired to design the intestine-targeted formulation using azoreductase as a target, the biodegradable polymer may be a polymer containing an azoaromatic linkage, for example, a copolymer of styrene and hydroxyethylmethacrylate (HEMA). When the polymer is added to the formulation containing the active ingredient, the active ingredient may be liberated into the intestine by reduction of an azo group of the polymer via the action of the azoreductase which is specifically secreted by enteric bacteria, for example, Bacteroides fragilis and Eubacterium limosum.
[0098] When it is desired to design the intestine-targeted formulation using glycosidase, esterase, or polysaccharidase as a target, the biodegradable polymer may be a naturally-occurring polysaccharide or a substituted derivative thereof. For example, the biodegradable polymer may be at least one selected from the group consisting of dextran ester, pectin, amylose, ethyl cellulose and a pharmaceutically acceptable salt thereof. When the polymer is added to the active ingredient, the active ingredient may be liberated into the intestine by hydrolysis of the polymer via the action of each enzyme which is specifically secreted by enteric bacteria, for example, Bifidobacteria and Bacteroides spp. These polymers are natural materials, and have an advantage of low risk of in vivo toxicity.
[0099] The intestine-targeted formulation (3) using the biodegradable matrix which is decomposable by an intestine-specific bacterial enzyme may be a form in which the biodegradable polymers are cross-linked to each other and are added to the active ingredient or the active ingredient-containing formulation. Examples of the biodegradable polymer may include naturally-occurring polymers such as chondroitin sulfate, guar gum, chitosan, pectin, and the like. The degree of drug release may vary depending upon the degree of cross-linking of the matrix-constituting polymer.
[0100] In addition to the naturally-occurring polymers, the biodegradable matrix may be a synthetic hydrogel based on N-substituted acrylamide. For example, there may be used a hydrogel synthesized by cross-linking of N-tert-butylacryl amide with acrylic acid or copolymerization of 2-hydroxyethyl methacrylate and 4-methacryloyloxyazobenzene, as the matrix. The cross-linking may be, for example an azo linkage as mentioned above, and the formulation may be a form where the density of cross-linking is maintained to provide the optimal conditions for intestinal drug delivery and the linkage is degraded to interact with the intestinal mucous membrane when the drug is delivered to the intestine.
[0101] Further, the intestine-targeted formulation (4) with time-course release of the drug after a lag time is a drug delivery system utilizing a mechanism that is allowed to release the active ingredient after a predetermined time irrespective of pH changes. In order to achieve enteric release of the active drug, the formulation should be resistant to the gastric pH environment, and should be in a silent phase for 5 to 6 hours corresponding to a time period taken for delivery of the drug from the body to the intestine, prior to release of the active ingredient into the intestine. The time-specific delayed-release formulation may be prepared by addition of the hydrogel prepared from copolymerization of polyethylene oxide with polyurethane.
[0102] Specifically, the delayed-release formulation may have a configuration in which the formulation absorbs water and then swells while it stays within the stomach and the upper digestive tract of the small intestine, upon addition of a hydrogel having the above-mentioned composition after applying the drug to an insoluble polymer, and then migrates to the lower part of the small intestine which is the lower digestive tract and liberates the drug, and the lag time of drug is determined depending upon a length of the hydrogel.
[0103] As another example of the polymer, ethyl cellulose (EC) may be used in the delayed-release dosage formulation. EC is an insoluble polymer, and may serve as a factor to delay a drug release time, in response to swelling of a swelling medium due to water penetration or changes in the internal pressure of the intestines due to a peristaltic motion. The lag time may be controlled by the thickness of EC. As an additional example, hydroxypropylmethyl cellulose (HPMC) may also be used as a retarding agent that allows drug release after a given period of time by thickness control of the polymer, and may have a lag time of 5 to 10 hours.
[0104] In the oral pharmaceutical composition according to the present invention, the active ingredient may have a crystalline structure with a high degree of crystallinity, or a crystalline structure with a low degree of crystallinity.
[0105] As used herein, the term “degree of crystallinity” is defined as the weight fraction of the crystalline portion of the total crystalline compound and may be determined by a conventional method known in the art. For example, measurement of the degree of crystallinity may be carried out by a density method or precipitation method which calculates the crystallinity degree by previous assumption of a preset value obtained by addition and/or reduction of appropriate values to/from each density of the crystalline portion and the amorphous portion, a method involving measurement of the heat of fusion, an X-ray method in which the crystallinity degree is calculated by separation of the crystalline diffraction fraction and the noncrystalline diffraction fraction from X-ray diffraction intensity distribution upon X-ray diffraction analysis, or an infrared method which calculates the crystallinity degree from a peak of the width between crystalline bands of the infrared absorption spectrum.
[0106] In the oral pharmaceutical composition according to the present invention, the crystallinity degree of the active ingredient is preferably 50% or less. More preferably, the active ingredient may have an amorphous structure from which the intrinsic crystallinity of the material was completely lost. The amorphous compound exhibits a relatively high solubility, as compared to the crystalline compound, and can significantly improve a dissolution rate and in vivo absorption rate of the drug.
[0107] In one preferred embodiment of the present invention, the amorphous structure may be formed during preparation of the active ingredient into microparticles or fine particles (micronization of the active ingredient). The microparticles may be prepared, for example by spray drying of active ingredients, melting methods involving formation of melts of active ingredients with polymers, co-precipitation involving formation of co-precipitates of active ingredients with polymers after dissolution of active ingredients in solvents, inclusion body formation, solvent volatilization, and the like. Preferred is spray drying. Even when the active ingredient is not of an amorphous structure, that is, has a crystalline structure or semi-crystalline structure, micronization of the active ingredient into fine particles via mechanical milling contributes to improvement of solubility, due to a large specific surface area of the particles, consequently resulting in improved dissolution rate and bioabsorption rate of the active drug.
[0108] The spray drying is a method of making fine particles by dissolving the active ingredient in a certain solvent and the spray-drying the resulting solution. During the spray-drying process, a high percent of the crystallinity of the naphthoquinone compound is lost to thereby result in an amorphous state, and therefore the spray-dried product in the form of a fine powder is obtained.
[0109] The mechanical milling is a method of grinding the active ingredient into fine particles by applying strong physical force to active ingredient particles. The mechanical milling may be carried out by using a variety of milling processes such as jet milling, ball milling, vibration milling, hammer milling, and the like. Particularly preferred is jet milling which can be carried out using an air pressure, at a temperature of less than 40° C.
[0110] Meanwhile, irrespective of the crystalline structure, a decreasing particle diameter of the particulate active ingredient leads to an increasing specific surface area, thereby increasing the dissolution rate and solubility. However, an excessively small particle diameter makes it difficult to prepare fine particles having such a size and also brings about agglomeration or aggregation of particles which may result in deterioration of the solubility. Therefore, in one preferred embodiment, the particle diameter of the active ingredient may be in a range of 5 nm to 500 μm. In this range, the particle agglomeration or aggregation can be maximally inhibited, and the dissolution rate and solubility can be maximized due to a high specific surface area of the particles.
[0111] Preferably, a surfactant may be additionally added to prevent the particle agglomeration or aggregation which may occur during formation of the fine particles, and/or an antistatic agent may be additionally added to prevent the occurrence of static electricity.
[0112] If necessary, a moisture-absorbent material may be further added during the milling process. The compound of Formula 1 or Formula 2 has a tendency to be crystallized by water, so incorporation of the moisture-absorbent material inhibits recrystallization of the naphthoquinone-based compound over time and enables maintenance of increased solubility of compound particles due to micronization. Further, the moisture-absorbent material serves to suppress coagulation and aggregation of the pharmaceutical composition while not adversely affecting therapeutic effects of the active ingredient.
[0113] Examples of the surfactant may include, but are not limited to, anionc surfactants such as docusate sodium and sodium lauryl sulfate; cationic surfactants such as benzalkonium chloride, benzethonium chloride and cetrimide; nonionic surfactants such as glyceryl monooleate, polyoxyethylene sorbitan fatty acid ester, and sorbitan ester; amphiphilic polymers such as polyethylene-polypropylene polymer and polyoxyethylene-polyoxypropylene polymer (Poloxamer), and Gelucire™ series (Gattefosse Corporation, USA); propylene glycol monocaprylate, oleoyl macrogol-6-glyceride, linoleoyl macrogol-6-glyceride, caprylocaproyl macrogol-8-glyceride, propylene glycol monolaurate, and polyglyceryl-6-dioleate. These materials may be used alone or in any combination thereof.
[0114] Examples of the moisture-absorbent material may include, but are not limited to, colloidal silica, light anhydrous silicic acid, heavy anhydrous silicic acid, sodium chloride, calcium silicate, potassium aluminosilicate, calcium aluminosilicate, and the like. These materials may be used alone or in any combination thereof.
[0115] Some of the above-mentioned moisture absorbents may also be used as the antistatic agent.
[0116] The surfactant, antistatic agent, and moisture absorbent are added in a certain amount that is capable of achieving the above-mentioned effects, and such an amount may be appropriately adjusted depending upon micronization conditions. Preferably, the additives may be used in a range of 0.05 to 20% by weight, based on the total weight of the active ingredient.
[0117] In one preferred embodiment, during formulation of the pharmaceutical composition according to the present invention into preparations for oral administration, water-soluble polymers, solubilizers and disintegration-promoting agents may be further added. Preferably, formulation of the composition into a desired dosage form may be made by mixing the additives and the particulate active ingredient in a solvent and spray-drying the mixture.
[0118] The water-soluble polymer is of help to prevent aggregation of the particulate active ingredients, by rendering surroundings of naphthoquinone-based compound molecules or particles hydrophilic to consequently enhance water solubility, and preferably to maintain the amorphous state of the active ingredient compound of Formula 1 or Formula 2.
[0119] Preferably, the water-soluble polymer is a pH-independent polymer, and can bring about crystallinity loss and enhanced hydrophilicity of the active ingredient, even under the between- and within-individual variation of the gastrointestinal pH.
[0120] Preferred examples of the water-soluble polymers may include at least one selected from the group consisting of cellulose derivatives such as methyl cellulose, hydroxymethyl cellulose, hydroxyethyl cellulose, ethyl cellulose, hydroxyethylmethyl cellulose, carboxymethyl cellulose, hydroxypropylmethyl cellulose, hydroxypropylmethyl cellulose phthalate, sodium carboxymethyl cellulose, and carboxymethylethyl cellulose; polyvinyl alcohols; polyvinyl acetate, polyvinyl acetate phthalate, polyvinylpyrrolidone (PVP), and polymers containing the same; polyalkene oxide or polyalkene glycol, and polymers containing the same. Preferred is hydroxypropylmethyl cellulose.
[0121] In the pharmaceutical composition of the present invention, an excessive content of the water-soluble polymer which is higher than a given level provides no further increased solubility, but disadvantageously brings about various problems such as overall increases in the hardness of the formulation, and non-penetration of an eluent into the formulation, by formation of films around the formulation due to excessive swelling of water-soluble polymers upon exposure to the eluent. Accordingly, the solubilizer is preferably added to maximize the solubility of the formulation by modifying physical properties of the compound of Formula 1 or Formula 2.
[0122] In this respect, the solubilizer serves to enhance solubilization and wettability of the sparingly-soluble compound of Formula 1 or Formula 2, and can significantly reduce the bioavailability variation of the naphthoquinone-based compound originating from diets and the time difference of drug administration after dietary uptake. The solubilizer may be selected from conventionally widely used surfactants or amphiphiles, and specific examples of the solubilizer may refer to the surfactants as defined above.
[0123] The disintegration-promoting agent serves to improve the drug release rate, and enables rapid release of the drug at the target site to thereby increase bioavailability of the drug.
[0124] Preferred examples of the disintegration-promoting agent may include, but are not limited to, at least one selected from the group consisting of Croscarmellose sodium, Crospovidone, calcium carboxymethylcellulose, starch glycolate sodium and lower substituted hydroxypropyl cellulose. Preferred is Croscarmellose sodium.
[0125] Upon taking into consideration various factors as described above, it is preferred to add 10 to 1000 parts by weight of the water-soluble polymer, 1 to 30 parts by weight of the disintegration-promoting agent and 0.1 to 20 parts by weight of the solubilizer, based on 100 parts by weight of the active ingredient.
[0126] In addition to the above-mentioned ingredients, other materials known in the art in connection with formulation may be optionally added, if necessary.
[0127] The solvent for spray drying is a material exhibiting a high solubility without modification of physical properties thereof and easy volatility during the spray drying process. Preferred examples of such a solvent may include, but are not limited to, dichloromethane, chloroform, methanol, and ethanol. These materials may be used alone or in any combination thereof. Preferably, a content of solids in the spray solution is in a range of 5 to 50% by weight, based on the total weight of the spray solution.
[0128] The above-mentioned intestine-targeted formulation process may be preferably carried out for formulation particles prepared as above.
[0129] In one preferred embodiment, the oral pharmaceutical composition according to the present invention may be formulated by a process comprising the following steps:
[0130] (a) adding the compound of Formula 1 or Formula 2 alone or in combination with a surfactant and a moisture-absorbent material, and grinding the compound of Formula 1 with a jet mill to prepare active ingredient microparticles;
[0131] (b) dissolving the active ingredient microparticles in conjunction with a water-soluble polymer, a solubilizer and a disintegration-promoting agent in a solvent and spray-drying the resulting solution to prepare formulation particles; and
[0132] (c) dissolving the formulation particles in conjunction with a pH-sensitive polymer and a plasticizer in a solvent and spray-drying the resulting solution to carry out intestine-targeted coating on the formulation particles.
[0133] The surfactant, moisture-absorbent material, water-soluble polymer, solubilizer and disintegration-promoting agent are as defined above. The plasticizer is an additive added to prevent hardening of the coating, and may include, for example polymers such as polyethylene glycol.
[0134] Alternatively, formulation of the active ingredient may be carried out by sequential or concurrent spraying of vehicles of step (b) and intestine-targeted coating materials of step (c) onto jet-milled active ingredient particles of step (a) as a seed.
[0135] Pharmaceutical compositions suitable for use in the present invention include compositions in which the active ingredients are contained in an amount effective to achieve its intended purpose. More specifically, a therapeutically effective amount means an amount of compound effective to prevent, alleviate or ameliorate symptoms of disease or prolong the survival of the subject being treated. Determination of a therapeutically effective amount is well within the capability of those skilled in the art, especially in light of the detailed disclosure provided herein.
[0136] When the pharmaceutical composition of the present invention is formulated into a unit dosage form, the compound of Formula 1 or Formula 2 as the active ingredient is preferably contained in a unit dose of about 0.1 to 1,000 mg. The amount of the compound of Formula 1 or Formula 2 administered will be determined by the attending physician, depending upon body weight and age of patients being treated, characteristic nature and the severity of diseases. However, it is general that the amount of administration necessary for treatment of adult is in the range of about 1 to 3000 mg per day depending upon the frequency and intensity of administration. Generally, about 1 to 500 mg per day as a total administration amount is sufficient for the intramuscular or intravenous administration to adult; however, more administration amount would be desired for some patients.
[0137] In accordance with another aspect of the present invention, there is provided a use of a compound of Formula 1 or 2 in the preparation of a medicament for the treatment and prevention of kidney diseases.
[0138] Examples of the kidney disease may include glomerulonephritis, diabetic nephropathy, chronic renal failure, acute renal failure, subacute renal failure, malignant nephrosclerosis, thrombotic microangiopathy syndromes, transplant rejection, glomerulopathies, renal hypertrophy, renal hyperplasia, proteinuria, contrast medium-induced nephropathy, toxin-induced renal injury, oxygen free radical-mediated nephropathy and nephritis.
[0139] The term “treatment” means ceasing or delaying progress of diseases when the compounds of Formula 1 or 2 or compositions comprising the same are administered to subjects exhibiting symptoms of diseases. The term “prevention” means ceasing or delaying symptoms of diseases when the compounds of Formula 1 or 2 or compositions comprising the same are administered to subjects exhibiting no symptoms of diseases, but having high risk of developing symptoms of diseases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0140] FIG. 1 is a graph showing serum creatinine levels as measured in acute renal failure-induced animals according to Experimental Example 1;
[0141] FIG. 2 is a graph showing BUN levels as measured in acute renal failure-induced animals according to Experimental Example 1;
[0142] FIG. 3 is a graph showing glycosylated hemoglobin levels as measured in diabetic nephropathy-induced animals according to Experimental Example 2;
[0143] FIG. 4 is a graph showing left kidney weights as measured in diabetic nephropathy-induced animals according to Experimental Example 2;
[0144] FIG. 5 is a graph showing urine albumin levels as measured in diabetic nephropathy-induced animals according to Experimental Example 2; and
[0145] FIG. 6 is a graph showing daily urine protein levels as measured in diabetic nephropathy-induced animals according to Experimental Example 2.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0146] Now, the present invention will be described in more detail with reference to the following Examples. These examples are provided only for illustrating the present invention and should not be construed as limiting the scope and spirit of the present invention.
[0147] Therapeutic effects of the pharmaceutical composition in accordance with the present invention will be confirmed as follows.
Materials and Methods
1. Assay of Serum Creatinine Level
[0148] Creatine is non-enzymatically converted into creatinine that is a waste product of muscle energy metabolism. Creatinine is a waste by-product and is therefore filtered by the kidney, but not reabsorbed. Since the muscle mass is generally maintained at a constant level and is less susceptible to other organs except for the kidney, a serum creatinine level is a good marker of the glomerular filtration rate. A higher creatinine concentration reflects more significant impairment of renal function. For example, a two-fold increase of the creatinine level represents a 50% decrease of the glomerular filtration rate.
2. Assay of Blood Urea Nitrogen (BUN) Level
[0149] Accumulation of toxic ammonia in the body is prevented in a manner that ammonia is produced by deamination of amino acids during a protein metabolic process and is then converted into urea in the liver. When excretory function of the kidney is compromised, the blood urea nitrogen level is elevated. Therefore, measurement of BUN is an important indicator to examine whether the kidney is normally functional or not. When the BUN level is elevated over a normal value, the subject is suspected to have acute nephritis, chronic nephritis, prostate hyperplasia or the like. When the BUN level is dropped below a normal value, the subject is suspected to have diabetes insipidus, muscular dystrophy or the like.
3. Assay of Glycosylated Hemoglobin (HbA1c)
[0150] When the blood glucose level is elevated, glucose in the blood partially binds to hemoglobin in red blood cells, producing glycosylated hemoglobin (termed HbA1c). When glycosylated hemoglobin is formed, the corresponding red blood cells will retain HbA1c until the red blood cells complete their lives to be destroyed. When the high blood glucose level lasts for a long period of time, a level of HbA1c in red blood cells is correspondingly increased. The HbA1c reflect a blood glucose value over a relatively long period of time, so the measurement of the HbA1c level may be a useful indicator of how well diabetes has been therapeutically controlled over the past several months.
4. Assay of Urine Albumin and Urine Proteins
[0151] An increase in the rate of excretion of albumin in the urine is the most preceding clinical finding in diabetic nephropathy. Therefore, an increased level of urine albumin is an indicator of renal or hepatic diseases.
Experimental Example 1
Effects of Inventive Compounds on Acute Renal Failure
[0152] Among compounds of Formula 1, effects of 7,8-dihydro-2,2-dimethyl-2H-naphtho(2,3-b)dihydropyran-7,8-dione (hereinafter, referred to as “compound of Example 1”) on acute renal failure were examined. For this purpose, 6-week-old male Sprague-Dawley rats, weighing 200 to 220 g (Japan SLC, Inc., Japan) were divided into two groups as given in Table 1 below: a vehicle-treated control group and a group received the compound of Example 1 (200 mg/kg). Animals were given test samples by the oral route. After two-week treatments were complete, acute renal failure was induced in rats.
[0000]
TABLE 2
Dose
n Number
Group name
Control
SLS 10 mg/kg (vehicle)
12
Control
Example 1
Compound of Example 1
12
MB 660
administered
200 mg/kg
[0153] Acute renal failure (ARF) was induced according to the following procedure. Ischaemia/reperfusion (IR) injury was made by anaesthesia of SD rats with an intramuscular injection of a mixture of ketamine and rompun (9:1, kg/mL) and abdominal shaving and opening, followed by clip ligation of renal arteries and veins for 30 min to induce ischaemia. During the abdominal operation, the body temperature of rats was maintained in the range of 36.0±0.5° C. After 30 min, the ligation clips were removed to allow for reperfusion, followed by abdominal suture.
[0154] Following the IR induction, 0.2 mL of serum was sampled from each animal on +1 day, +3 day and +5 day, respectively. Creatinine and BUN (blood urea nitrogen) levels were measured with an automatic biochemical analyzer (HITACHI, 7020). The results obtained are shown in FIGS. 1 and 2 , respectively.
[0155] Referring to FIG. 1 showing the serum creatinine levels as measured, it can be confirmed that a content of creatinine in the serum was significantly decreased in the group with administration of the compound of Example 1 in accordance with the present invention (MB 660), when compared to the control group. Such a decrease of serum creatinine was most prominent particularly after 3 days of reperfusion.
[0156] Referring to FIG. 2 , the MB 660 group also exhibited a significant reduction of serum BUN, as compared to the control group. As confirmed, a drop of the serum BUN level was most remarkable after 3 days of reperfusion.
[0157] As can be seen from these experimental results, administration of the compound of Example 1 resulted in elevation of the glomerular filtration rate, thus suggesting that the compound of the present invention has excellent therapeutic effects on kidney diseases.
Experimental Example 2
Effects of Inventive Compounds on Diabetic Nephropathy
[0158] 8-week-old male Zucker diabetic fatty (ZDF) rats (Charles River Laboratory) were divided into four groups as given in Table 2 below: Vehicle, MB660 (250 mg/kg), Pair-fed, and Rosi (6 mg/kg). Animals were orally given test samples.
[0000]
TABLE 3
Dose
n Number
Group names
Control
SLS 10 mg/kg (vehicle)
5 (4)
Control
Example 1
Compound of Example 1
8 (6)
MB 660
administered
250 mg/kg
Control diet-fed
SLS 10 mg/kg
5 (4)
Pair-fed
Comp. Ex. 1
Rosiglitazone 6 mg/kg
6 (5)
Rosi
[0159] Diabetic nephropathy model animals were fed with a low-fat feed (11.9 kcal % fat, 5053, Labdiet). Animals with a blood glucose level of 300 mg/dl and a body weight (BW) of more than 300 g were selected and treated with test samples for 4 and 8 weeks, respectively (total 12 and 16 weeks old). In-vivo changes in glycosylated hemoglobin (HbA1c), urine albumin and urine protein (1,000× urine albumin/urine creatinine) associated with kidney diseases were observed. The results obtained are shown in FIGS. 3 to 6 . Albumin was measured using an immunoturbidimetric assay, and creatinine was measured using a Jaffe rate method.
[0160] Referring to FIG. 3 , a value of glycosylated hemoglobin (Hb A1c ) was significantly low in the group (MB 660) with administration of the compound of Example 1 in accordance with the present invention, thus confirming that blood glucose control was improved. Further, as shown in FIG. 4 , the diabetic nephropathy-induced group (control) exhibited an increase in the left kidney weight, whereas the MB 660 group exhibited a significant decrease in the left kidney weight.
[0161] In addition, a urine albumin level (see FIG. 5 ) and a daily urine protein level as calculated by 1000× urine albumin/urine creatinine (see FIG. 6 ) were lower in the MB 660 group than in the Rosiglitazone-administered group (Rosi), thus representing that albuminuria and proteinuria were significantly decreased in response to administration of the compound of the present invention. From these results, it can be seen that the compound of Example 1 in accordance with the present invention has superior therapeutic effects on diabetic nephropathy, as compared to Rosiglitazone.
INDUSTRIAL APPLICABILITY
[0162] As apparent from the foregoing, a pharmaceutical composition in accordance with the present invention increases a glomerular filtration rate, controls blood glucose and decreases proteinuria to thereby have excellent effects on the treatment and prevention of kidney diseases such as acute renal failure, diabetic nephropathy, etc.
[0163] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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Provided is a pharmaceutical composition for the treatment and prevention of kidney diseases, containing (a) a therapeutically effective amount of a compound represented by Formulae 1 or 2 or a pharmaceutically acceptable salt, prodrug, solvate or isomer thereof, and (b) a pharmaceutically acceptable carrier, diluent or excipient or any combination thereof.
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This is a divisional of pending application Ser. No. 07/532,768, filed Jun. 4, 1990, now U.S. Pat. No. 5,093,353, issued Mar. 3, 1988, which is a division of application Ser. No. 07/196,996 filed May 20, 1988 and issued as U.S. Pat. No. 4,950,684 on Aug. 21, 1990.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel compounds of Formula I having a 2,2-di-substituted chromanonyl (benzopyran) ring-structure which are antagonists of leukotriene D 4 (LTD 4 ) and the slow reacting substance of anphylaxis (SRS-A). In particular, the compounds of this invention are useful as pharmaceutical agents to prevent or alleviate the symptoms associated with LTD 4 , such as allergic reactions and inflammatory conditions.
LTD 4 is a product of the 5-lipoxygenase pathway and is the major active constitutent of slow reacting substance of anaphylaxis (SRS-A), a potent bronchonconstrictor that is released during allergic reactions. See R. A. Lewis and K. F. Austen, Nature, 293, 103-108 (1961). When administered to humans and guinea pigs, LTD 4 causes bronchoconstriction by two mechanisms: (1) directly, by stimulating smooth muscle; and (2) indirectly, through release of thromboxin A 2 which then causes contraction of respiratory smooth muscle. Because antihistamines are ineffective in the management of asthma, SRS-A and not histamine is believed to be a mediator of the bronchoconstriction occurring during an allergic attack. LTD 4 may also be involved in other inflammatory conditions such as rheumatoid arthritis. Furthermore, LTD 4 is a potent coronary vasoconstrictor and influences contractile force in the myocardium and coronary flow rate of the isolated heart. See F. Michelassi, et al., Science, 217, 841 (1982); J. A. Burke, et al., J. Pharmacol, and Exp. Therap., 221, 235 (1982).
2. Prior Art
Appleton, et al., J. Med. Chem., 20, 371-379 (1977) discloses a series of chromone-2-carboxylic acids having a single substituent in the 2-position, which are antagonists of SRS-A. Specifically, sodium 7-[3-(4-acetyl-3-hydroxy-2-propylphenoxy)-2-hydroxypropoxy]-4-oxo-8-propyl-4H-1-benzopyran-2-carboxylate (FPL 55712), appears to be the first reported specific antagonist of SRS-A and LTD 4 .
Miyano, et al., (U.S. Pat. No. 4,546,194) discloses substituted chromanon-2-yl alkanols and derivatives thereof which are useful as LTD 4 inhibitors. In Miyano, the LTD 4 inhibitors have two substituents at the two position of their chromane ring, one of which is alkyl. Moreover, Miyano discloses a diether at position 7 which has 4-acetyl-3-hydroxy-2-propylphenoxy as the substituent at its terminus.
Similar references disclosing chromane compounds which are useful as LTD 4 antagonists are the following: European Patent Application Nos. 0079637, 129,906, and 150,447; U.S. Pat. No. 4,565,882; Japanese patent 60/42378; and C. A. 103(19) 160 389 G.
SUMMARY OF THE INVENTION
This invention encompasses a compound of the formula: ##STR3## or a pharmaceutically acceptable addition salt thereof, wherein R 1 is methyl, phenyl, ##STR4## wherein X 1 and X 2 may be the same or different and are hydrogen, --Cl, --Br, --CF 3 , --NH 2 , --NO 2 , or straight or branched chain alkyl of 1-3 carbon atoms;
wherein m is an integer from 1-9;
wherein n is an integer from 1-5;
wherein V is ##STR5## --CH(OH)--, or --CH 2 --; wherein W is hydrogen or straight or branched chain alkyl of 1-6 carbon atoms;
wherein Y is hydrogen or --COCH 3 ;
wherein Z is --CHO, --COOR 2 , --COR 3 , ##STR6## or CH 2 OR 4 with the proviso that when one moiety of Formula I is COOR 2 , the other Z moiety may optionally be COR 3 ;
wherein R 2 is hydrogen, a pharmaceutically acceptable cation, straight or branched chain alkyl having 1-6 carbon atoms, ##STR7## or --CH(CH 2 OR 5 ) 2 with the proviso that when Z is --COOR 2 , the R 2 substituent in one --COOR 2 moiety may be the same or different from the R 2 substituent in the other COOR 2 moiety;
wherein R 3 is ##STR8## and wherein R 7 and R 8 may be the same or different and are members of the group comprising hydrogen or straight or branched chain lower alkyl having 1-6 carbon atoms; or wherein N, R 7 and R 8 may together form a cyclic amine of the formula ##STR9## wherein p is 4 or 5; wherein R 4 is hydrogen, or ##STR10## wherein R 5 is hydrogen, benzyl-, or straight or branched chain alkyl of 1-3 carbon atoms; and
wherein R 6 is a member of the group comprising straight or branched chain alkyl having 1-6 carbon atoms.
DETAILED DESCRIPTION
This invention relates to novel LTD 4 inhibitors of Formula I having a chromane ring structure and 2,2-disubstitution on the chromane ring. The disubstituents of the present invention are of the formula --(CH 2 ) m --Z wherein Z is a carbonyl containing moiety such as --CHO, --COOR 2 , or --COR 3 , i.e. an aldehyde, ester, or amide respectively; or an alcohol, i.e. the reduction product of the above carbonyls; or the corresponding lower alkyl ester of said alcohol.
The term "lower alkyl" as used herein means straight or branched chain alkyl having 1-6 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, hexyl and the isomeric forms thereof.
The term "pharmaceutically acceptable cation" as used to describe R 2 refers to cations such as ammonium, sodium, potassium, lithium calcium, magnesium, ferrous, zinc, copper, manganous, aluminum, ferric, manganic, ammonium, tetraalkylammonium, and the like.
The term "pharmaceutically acceptable addition salts" refers either to those base derived salts of any compound herein having a carboxylic acid function, or to those acid derived salts of any compound herein having an amide function.
The base derived salts may be derived from pharmaceutically acceptable non-toxic inorganic or organic bases. Among the inorganic bases employed to produce said pharmaceutically acceptable salts are the hydroxide bases of the pharmaceutically acceptable cations disclosed above.
Among the organic bases employed to produce said pharmaceutically acceptable salts are the pharmaceutically acceptable non-toxic bases of primary, secondary, and tertiary amines. Especially preferred non-toxic bases are isopropylamine, diethylamine, ethanolamine, dicyclohexylamine, choline, and caffein.
The acid derived salts may be derived from pharmaceutically acceptable non-toxic organic or inorganic acids. Suitable pharmaceutically acceptable organic acid salts include such salts as the maleate, fumarate, tartrate, (methane-, ethane-, and benzene) sulfonates, citrate, and the malate. Suitable inorganic (mineral) acid salts include such salts as the chloride, bromide, and sulfate.
All the pharmaceutically acceptable non-toxic addition salts are prepared by conventional processes well known to those of ordinary skill in the art.
LTD 4 acts by causing brochoconstriction in both guinea pigs and humans. The bronchoconstriction has two components: (1) a direct component, wherein LTD 4 stimulates the respiratory smooth muscle to constrict; and (2) an indirect component wherein LTD 4 causes the release of thromboxane A2 which also causes the construction of respiratory smooth muscle. The compounds of this invention act by antagonizing the direct constriction of respiratory smooth muscle by LTD 4 .
The LTD 4 antagonistic activity of the compounds of this invention were determined by both in vivo and in vitro testing upon guinea pigs. In one in vivo assay, adult male fasted Hartly guinea pigs weighing 300-360 g were pretreated with pyrilamine and indomethacin to block the bronchoconstrictive effects of endogenous histamine and the synthesis of thromboxane A2 respectively. Compounds of the invention were administered IG (intragastrically) at approximate times prior to the IV (intravenous) administration of 2000 units of LTD 4 . Intratracheal pressure was monitored prior to and subsequent to LTD 4 administration in animals anesthetized with pentobarbital and attached to a rodent respirator. A compound was determined to antagonize the direct component of LTD 4 action on respiratory smooth muscle if the compound inhibited the intratracheal insufflation pressure increases caused by LTD 4 . The compounds of this invention were found to exhibit LTD 4 antagonistic activity at doses of 10 mg/kg.
One of the in vitro assays utilized to determine the LTD 4 antagonistic activity of the compounds of this invention was performed on excised guinea pig ileum (smooth muscle). In this assay, control contractions of guinea pig ileum ("ileum") were incubated in a solution of LTD 4 and the number of contractions in response to LTD 4 were determined. A solution or suspension containing a compound of this invention was substituted for the control solution and the item was allowed to incubate for 30 minutes. Thereafter, doses of LTD 4 were added and increased if necessary until contractions were obtained that are approximately equal to the control. A dose/test compound ratio was calculated from the results of each test. A concentration of the test compound was judged to be active if it produced a dose ratio that was significantly greater than that obtained in a series of blank treatment tests. Duplicate tests were conducted on each concentration of test compound. Initial screening of the compounds of this invention began at 3×10 -6 M. The compounds of the present invention were determined to exhibit LTD 4 antagonistic activity at test concentration ranging from 3×10 -6 M to 1×10 -7 M.
By virtue of their activity as LTD 4 inhibitors, the compounds of Formula I are useful in treating inflammatory conditions in mammals in which LTD 4 plays a role such as psoriasis, Chrohn's disease, asthmatic bronchitis, ulcerative colitis and the like. A physician or veterinarian or ordinary skill can readily determine whether a subject exhibits the inflammatory condition. The preferred utility relates to treatment of ulcerative colitis.
The compounds can be administered in such oral dosage forms as tablets, capsules, softgels, pills, powders, granules, elixirs, or syrups. The compounds may also be administered intravascularly, intraperitoneally, subcutaneously, intramuscularly, or topically using forms known to the pharmaceutical art. In general, the preferred form of administration is oral or in such a manner so as to localize the inhibitor. For example, for asthma, the compounds could be inhaled using an aerosol or other appropriate spray. In an inflammatory condition such as rheumatoid arthritis, the compounds could be injected directly into the affected joint.
For the orally administered pharmaceutical compositions and methods of the present invention the foregoing active ingredients will typically be administered in admixture with suitable pharmaceutical diluents, excipients, or carriers (collectively referred to herein as "carrier" materials) suitably selected with respect to the intended form of administration, that is, oral tablets, capsules, softgels, elixirs, syrups, drops, and the like, and consistent with conventional pharmaceutical practices.
For example, for oral administration in the form of tablets or capsules, the active drug components may be combined with ay oral non-toxic pharmaceutically acceptable inert carrier such as lactose, starch, sucrose, cellulose, magnesium stearate, dicalcium phosphate, calcium sulfate mannitol, and the like, or various combination thereof. For oral administration in liquid forms, such as in softgels, elixirs, syrups, drops and the like, the active drug components may be combined with any oral non-toxic pharmaceutically acceptable inert carrier such as water, saline, ethanol, polyethylene glycol, propylene glycol, corn oil, cottonseed oil, peanut oil, sesame oil, benzyl alcohol, various buffers, and the like, or various combinations thereof. Moreover, when desired or necessary, suitable binders, lubricants, disintegrating agents, and coloring agents can also be incorporated in the mixture. Suitable binders include starch, gelatin, natural sugars, corn sweeteners, natural and synthetic gums such as acacia, sodium alginate, carboxymethylcellulose, polyethylene glycol, and waxes, or combinations thereof. Lubricants for use in these dosage forms include boric acid, sodium benzoate, sodium acetate, sodium chloride, and the like, or combinations thereof. Disintegrators include, without limitation, starch, methylcellulose, agar, bentonite, guar gum, and the like, or combinations thereof. Sweetening and flavoring agents and preservatives can also be included where appropriate.
For intravascular, intraperitoneal, subcutaneous, intramuscular or aerosol administration, active drug components may be combined with a suitable carrier such as water, saline, aqueous dextrose, and the like. Regardless of the route of administration selected, the compounds of the present invention are formulated into pharmaceutically acceptable dosage forms by conventional methods known to those skilled in the art. The compounds may also be formulated using pharmacologically acceptable acid or base addition salts. Moreover, the compounds or their salts may be used in a suitable hydrated form.
Regardless of the route of administration selected, a non-toxic but therapeutically effective quantity of one or more compounds of this invention is employed in any treatment. The dosage regimen for preventing or treating inflammatory conditions with the compounds of this invention is selected in accordance with a variety of factors, including the type, age, weight, sex, and medical condition of the patient, the severity of the inflammatory condition, the route of administration, and the particular compound employed in the treatment. A physician or veterinarian of ordinary skill can readily determine and prescribe the effective amount of the drug required to prevent or arrest the progress of the condition. In so proceeding, the physician or veterinarian could employ relatively low doses at first and subsequently increase the dose until a maximum response is obtained.
The compounds of this invention are prepared by the general methods illustrated in Schemes A-E. In the discussion of these schemes, the conventional numbering of the chromane ring is employed as illustrated in Formula II below. ##STR11##
In charts A to E, the various compounds and intermediates can be readily modified by methods known to those skilled in the art. For example, esters can be hydrolyzed to corresponding carboxylic acids (and their respective addition salts), or converted to corresponding amides by appropriate reactions with amines, or reduced to alcohols by such reagents as lithium aluminium hydride (LiAlH 4 ). Such products and intermediates can, or course, be similarly interconverted.
As illustrated in Chart A, 2,4-dihydroxylacetophenones of Formula X, wherein W and Y are as defined herein, react readily with ketodiesters of Formula XI, such as dimethyl 4-oxopimelate where (n=2), to afford fused ring compounds of Formula XII or of Formulas XII and XIII depending upon reaction conditions. The preferred reaction conditions for condensation and cyclization to produce the compound of Formula XII include heating Formulas X and XI in toluene, in the presence of a base such as pyrrolidine, with provisions for removal of the water with an apparatus such as a Dean-Stark trap. Alternatively, to produce the compounds of both Formulas XII and XIII, the condensation and cyclization is allowed to proceed overnight at room temperature in the presence of a secondary amine, such as pyrrolidine, and then at reflux for about 3-4 hours.
The intermediates of Formulas XII and XIII may be used in reactions in Chart B without further modification or they may be converted to related intermediates of Formulas XIV and XV by methods known to those skilled in the art. For example, hydrogenation over palladium on carbon (Pd/C) will reduce the keto function of the dihydrobenzopyran-4-ones (Formulas XII or XIII) to the corresponding --CH 2 --, producing a dihydrobenzopyran of Formula XIV. Partial hydrogenation or reduction with NaBH 4 in a polar solvent will afford the corresponding 4-hydroxy compound of Formula XV. These latter two sequences of reactions provide the means for achieving the necessary diversity in "V" of Formula I.
As illustrated in Chart B, alcohols of the formula R 1 OH (XVIa) may be alkalyated to form ethers in the presence of an alkylating agent (XVIb) and a base. Preferably, the alcohol is methanol or hydroxyaryl. By "hydroxyaryl" is meant phenol, naphthol, 5,6,7,8-tetrahydronaphthols or substituted analogs thereof, wherein the substituents include --NH 2 , NO 2 , Cl, Br, CF 3 and lower alkyl from 1-4 carbon atoms. Preferably, the alkylating agent is a dihaloalkane of the formula X--(CH 2 ) m --X wherein X is Br, Cl or I and m is an integer from 1-9. Especially preferred as an alkylating agent is Br--(CH 2 ) m --Br. Preferred reaction conditions include reaction in dry dimethylformamide (DMF) in the presence of the anhydrous base, potassium carbonate.
Intermediates of Formula XVII are typically purified by column chromatography on silica gel. The further reaction of XVII with 7-hydroxybenzopyran-4-ones of Formula XII in the presence of base in polar aprotic solvents afford the diester pyranone ethers (XVIII) of this invention. Similarly, diester pyran and pyranol ethers can be afforded by reaction of XVII with pyrans of Formula XIV and pyranols of Formulas XV, respectively. Preferred reaction conditions for this ether formation include reaction in dry DMF in the presence of an anhydrous base, such as potassium carbonate.
Chart B further illustrates that the diesters XVIII may be hydrolyzed to the corresponding diacid salt XIX in the presence of a base. Preferably, the base is a hydroxide species having a pharmaceutically acceptable cation as disclosed herein. The preferred solvent system is aqueous alcohol, such as aqueous methanol. The resulting diacid salts XIX may be converted to the corresponding diacid species XX by acidification of XIX in an aqueous alcoholic solution. Preferred acidifying agents are the mineral acids such as HCl. H 2 SO 4 , H 3 PO 4 and the like.
Chart C illustrates the preparation of the compounds of Formula XVIII using a variation of the method of Chart B. The compounds of Formula XII are first reacted with dihaloalkanes of the formula, X--(CH 2 ) m --X, preferably Br--(CH 2 ) m --Br, in the presence of base in a polar solvent to produce an intermediate of Formula XXI. As in Chart B, the preferred conditions for ether formation include reaction in dry dimethyl formamide (DMF) in the presence of anhydrous potassium carbonate (K 2 CO 3 ). By the same general procedure for ether formation just employed in converting Formula XII to XXI above, Formulas XXI and X react in the presence of base in a polar solvent to form the title compounds of this invention, Formula XVIII.
Chart D illustrates a condensation reaction analogous to Chart A wherein 2,4-dihydroxyacetophenones of Formula X react with ketodienes of Formula XXX in the presence of a weak base in a nonpolar solvent with heat to afford the corresponding 2,2-bis-enylpyranone's of Formula XXXI. Preferred reaction conditions include toluene as the solvent and pyrrolidine as the weak base. Formula XXXI reacts with a halide XVII in a polar solvent, preferably dimethylformamide (DMF), in the presence of a base, preferably K 2 CO 3 , via a nucleophilic substitution to form the corresponding bis-(enyl)ether XXXII. The enyl groups of XXXII are oxidized to the vicinal diols of XXXIII by OsO 4 in aqueous alcoholic tetrahydrofuran (THF) in the presence of N-methylmorpholine-N-oxide. Preferably, the alcoholic portion of the solvent is t-butanol.
Chart E illustrates further reactions of the bis-diol XXXIII to yield the compounds of this invention. The bis-diol XXXIII may be esterified to a tetraester XXXIV by acetylation - reaction of the bis-diol with an excess of an alkyl or aryl anhydride such as acetic anhydride in the presence of a weak base, preferably pyridine. Alternatively, the bis-diol XXXIII can be oxidized to a bis-aldehyde, wherein the oxidized side chain loses one carbon atom. The preferred oxidizing agent is periodate (IO 4 --) associated with either H+ or an alkali metal cation.
In another reaction sequence in Chart E, the diester XVII is first converted to the diacyl chloride by reaction with thionyl chloride (SO 2 Cl) and then to the bis-(dibenzyl ester) XXXVI by reaction of the diacyl chloride with 1,3-dibenzyloxy-2-propanol. Partial hydrogenation of XXXVI over 10% Pd/C produces the tetra-ol XXXVII. Alternatively, the diester XVIII may be converted to the terminal bis-(diol ester) XXXVIII by reaction with glicidol in the presence of benzyl-trimethylammonium hydroxide.
It is recognized that certain compounds of this invention may exist in L, D and D, L forms. These stereoisomers may be separated into their individual enantimoners by techniques well known in the art, such as recrystallization and chromatography of their optically active derivatives.
The following examples are given by way of illustration only and should not be construed as limiting this invention either in spirit or in scope, as based upon the disclosure herein many variations will become obvious to those of ordinary skill in the art. ##STR12##
DESCRIPTION OF THE PREFERRED EMBODIMENT
EXAMPLE 1
diethyl 3,4-dihydro-4-oxo-7-hydroxy-8-propyl-2H-1-benzopyran-2,2-dipropanoate ##STR13##
A stirred solution of 12.3 g (53.5 mmol) of diethyl 4-oxopimelate, 10.4 g (53.5 mmol) of 2,4-dihydroxy-3-propylacetophenone, and 3.8 g (55 mmol) of pyrrolidine in 62 ml of toluene was refluxed under a water separator. After 4 hours, the mixture was allowed to cool. The solvent was removed under reduced pressure and the resultant oil was chromatographed on silica gel using ethyl acetate-hexane as eluent. The titled diester (4.98 g) was found to be homogeneous by thin-layer chromatography (20% by volume ethyl acetate/hexane on silica gel plates) and was used in subsequent reactions without further purification.
1 H NMR (CDCl 3 ): δ8.13(br s, 1H); 7.60(d, J=9 Hz, 1H); 6.50 (d, J=9 Hz, 1H); 4.12(q, J=7 Hz, 4H); 2.65(br s, 2H); 2.53-1.83(m, 10H); 1.52 (m, 2H); 1.22(q, J=7 Hz, 6H); and 0.95(t, 3H).
EXAMPLE 2
Mixture of ##STR14##
A stirred solution of 9.70 g (50 mmol) of 2,4-dihydroxy-3-propylacetophenone, 10.1 g (50 mmol) of dimethyl 4-oxopimelate, and 1.8 g of pyrrolidine in 62 ml of toluene was stirred overnight at room temperature, then refluxed under a water separator for 3.5 hours. The mixture was allowed to cool, and the solvent was removed under reduced pressure. Chromatography of the residue on silica gel using 20% ethyl acetate/toluene as eluent gave 1.39 g of the titled diester. The purified diester was found to be homogeneous by thin-layer chromatography (20% ethyl acetate/toluene by volume on silica gel plates) an was used in subsequent reactions without further purification. The titled ester-amide (590 mg) was obtained impure but was suitable for use in subsequent reactions.
Diester: 1 H NMR (CDCl 3 ): δ0.99(t, 3H); 1.21-1.75(m, 2H); 1.91-2.75(m, 10H); 2.66(s, 2H); 3.68(s, 6H); 5.91(br s, 1H); 6.45(d, 1H) and 7.63(d, 1H).
Ester-amide: 1 H NMR (CDCl 3 ): δ10.45(br s, 1H); 7.56(d, 1H); 6.64(d, 1H); 3.68(s, 3H); 2.82(br s, 2H); 1.57(m, 2H); and 1.01(t, 3H).
EXAMPLE 3 ##STR15##
To a suspension of 1.53 g (63.8 mmol) of sodium hydride in 50 ml of dry dimethylformamide was added over thirty minutes a solution of 8.23 g (63.8 mmol) of 4-chlorophenol. After stirring for one hour at room temperature, 16 g (77 mmol) of 1,3-dibromopropane was added in one portion. The mixture was stirred for 68 hours, and the solvent removed under reduced pressure. The residue was dissolved in diethyl ether and washed with water. The aqueous layer was then extracted twice with ether. The combined organic extracts were washed three times with water, once with brine, then dried (MgSO 4 ). After filtration, the solvent was removed under reduced pressure. The residue was chromatographed on silica gel, using 10% methylene chloride/hexane as the eluent and produced 710 mg of the title compound, which was homogenous by thin layer chromatography (10% by volume of methylene chloride/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ7.27(d, J=9 Hz, 2H); 6.85(t, J=9 Hz, 2H); 4.07 (t, 2H), 3.60(t, 2H); and 2.28(quintet, 2H).
EXAMPLE 4 ##STR16##
To a solution of 3.60 g (25 mmol) of 2-naphthol and 6.0 g (30 mmol) of 1,3-dibromopropane in dimethylformamide was added 7.25 g (52.5 mmol) of finely ground anhydrous potassium carbonate. The mixture was stirred vigorously overnight. Solvent was removed under reduced pressure. The residue was partitioned between ethyl acetate and water. The aqueous layer was further extracted twice with ethyl acetate. The combined organic extracts were dried over magnesium sulfate, and after filtration, the solvent was removed under reduced pressure. The residue was then chromatographed over silica gel using 10% methylene chloride/hexane as eluent to afford 1.66 g of the title compound, which was homogeneous by thin layer chromatography (5% by volume of ethyl acetate/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ7.73-6.90(m, 7H); 4.03(t, 2H); 3.50(t, 2H); and 2.22(quintet, 2H).
EXAMPLE 5 ##STR17##
The title compound was prepared by the method of Example 4 using 1-naphthol, 1.80 g (12.5 mmol), in place of 2-naphthol. After chromatography there was obtained 0.80 g of the title compound, which was homogeneous by thin layer chromatography (10% by volume of toluene/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ8.40-6.77(m, 7H); 4.22(t, 2H); 3.65(t, 2H); and 2.38(quintet, 2H).
EXAMPLE 6 ##STR18##
A mixture of 3.26 g (20 mmol) of 3,4-dichlorophenol, 20.2 g (100 mmol) of 1,3-dibromopropane, 6.80 g (20 mmol) of tetra-n-butyl ammonium hydrogen sulfate, 40 ml of 1N sodium hydroxide, and 40 ml of methylene chloride was stirred rapidly at reflux. After 2 hours, the mixture was allowed to cool and the layers were separated. The organic layer was washed with water, dried over magnesium sulfate, filtered and the solvent removed under reduced pressure. The residue was chromatographed over silica gel using methylene chloride/hexane as eluent. The title compound (1.58 g) was found to be homogeneous by thin layer chromatography (10% by volume of methylene chloride/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ7.29(d, J=9 Hz, 1H); 6.97(d, J=3 Hz, 1H); 6.71 (dd, J=3, J=9 Hz, 1H); 3.97(t, 3H); 3.57(t, 2H); 2.27(quintet, 2H).
EXAMPLE 7 ##STR19##
The title compound was prepared and worked up by the method of Example 6 using 4-bromophenol in place of 3,4-dichlorophenol. After chromatography the title compound (3.45 g) was found to be homogeneous by thin layer chromatography (10% by volume of methylene chloride/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ7.31(d, 2H); 6.71(d, 2H); 3.98(t, 2H); 3.50(t, 2H); and 2.20(quintet, 2H).
EXAMPLE 8 ##STR20##
The title compound was prepared and worked up according to the method of Example 6 using 4-chloro-1-naphthol (1.79 g) in place of 3,4-dichlorophenol. After chromatography, the title compound (2.09 g) was found to be homogeneous by thin layer chromatography (10% by volume of methylene chloride/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ8.13(m, 2H); 7.47(m, 2H); 7.30(d, J=8 Hz, 1H); 6.50(d, J=8 Hz, 1H); 4.00(t, 2H); 3.55(t, 2H); and 2.27(quintet, 2H).
EXAMPLE 9 ##STR21##
The title compound was prepared and worked up according to the method of Example 6 using 3-trifluoromethylphenol (1.62 g) in place of 3,4-dichlorophenol. After chromatography, the title compound (1.24 g) was found to be homogeneous by thin layer chromatography (10% by volume of methylene chloride/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ7.40-6.93(m, 4H); 4.10(t, 2H); 3.57(t, 2H); and 2.30(quintet, 2H).
EXAMPLE 10 ##STR22##
The title compound was prepared and worked up according to the method of Example 6 using 4-nitrophenol (1.39 g) in place of 3,4-dichlorophenol. After chromatography, the title compound (1.67 g) was found to be homogeneous by thin layer chromatography (10% or 20% by volume of ethyl acetate/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ8.16(d, 2H); 6.94(d, 2H); 4.22(t, 2H); 3.62 (t, 2H); and 2.37(quintet, 2H).
EXAMPLE 11 ##STR23##
The title compound was prepared by the method of Example 6 using 2-propylphenol (1.36 g) in place of 3,4-dichlorophenol. After chromatography, the title compound (1.59 g) was found to be homogeneous by thin layer chromatography (5% by volume of toluene/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ7.23-6.70(m, 4H); 4.07(t, 2H); 3.60(t, 2H); 2.60(t, 2H); 2.32(quintet, 2H); 1.55(m, 2H); and 0.95(t, 3H).
EXAMPLE 12 ##STR24##
The title compound was prepared by the method of Example 6 using 5,6,7,8-tetrahydro-1-naphthol in place of 3,4-dichlorophenol. After chromatography, the title compound (1.49 g) was found to be homogeneous by thin layer chromatography (10% by volume of methylene chloride/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ7.05(dd, J=8 Hz, 1H); 6.68(d, J=8 Hz, 1H); 6.53(d, J=8 Hz, 1H); 4.03(t, 2H); 3.60(t, 2H); 2.68(m, 4H); 2.28(quintet, 2H); and 1.75(m, 4H).
EXAMPLE 13 ##STR25##
A mixture of 1.52 g (10 mmol) of 4-acetoxyphenol, 2.22 g (11 mmol) 1,3-dibromopropane, and 2.980 g (21 mmol) of anhydrous potassium carbonate in dimethylformamide was stirred rapidly at room temperature for 4 hours. Ethyl acetate was added, and the salts present were removed by filtration. The solvent was removed under reduced pressure, and the residue chromatographed over silica gel. Elution with 15% ethyl acetate-hexane gave 270 mg of the title compound, which was homogeneous by thin layer chromatography (15% by volume of ethyl acetate/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ6.87(m, 4H); 4.02(t, 3H); 3.53(t, 2H); 2.33(quintet, 2H); and 2.22(s, 3H).
EXAMPLE 14 ##STR26##
The title compound was prepared and worked up by the method of Example 6 using 25.0 g of 2,4-dihydroxy-3-propylacetophenone in place of 3,4-dichlorophenol. After chromatography, the title compound (8.60 g) was found to be homogeneous by thin layer chromatography (10% by volume of ethyl acetate/hexane on silica gel plates).
1 H NMR (CDCl 3 ): δ7.60(d, 1H); 6.47(d, 1H); 4.19(t, 2H); 3.62(t, 2H); 2.63(t, 2H); 2.56(s, 3H); 2.36(quintet, 2H); 1.57(m, 2H); and 0.94(t, 3H).
EXAMPLE 15 ##STR27##
A stirred solution of 4.62 g (30.4 mmol) of 2,4-dihydroxyacetophenone, 7.00 g (30.4 mmol) of diethyl 4-oxopimelate, and 2.2 g (30 mmol) of pyrrolidine in 38 ml of toluene was refluxed under a water separator for 3.5 hours. After the mixture was allowed to cool, it was chromatographed directly over silica gel using ethyl acetate/hexane as eluent to produce 3.82 g of the title compound as a solid, m.p. 108.5°-109.5° C.
1 H NMR (CDCl 3 ): δ8.30(br s, 1H); 7.76(d, J=8 Hz, 1H); 6.58 (dd, J=8 Hz, J=2Hz, 1H); 6.40(d, J=2 Hz, 1H); 4.20(q, 4H); 2.78(br s, 1H); 2.68-1.98(m, 8H); and 1.32(t, 3H).
Analysis calculated for C 19 H 24 O 7 (MW=364.40):
Calcd.: C, 62.62; H, 6.64.
Found: C, 62.62; H, 6.39.
EXAMPLE 16 ##STR28##
A mixture of 1.00 g (2.65 mmol) of the title diester of Example 2, 684 mg (3.18 mmol) of 3-phenoxy-1-bromopropane, and 769 mg (5.57 mmol) of anhydrous potassium carbonate in 23 ml of dimethylformamide was stirred overnight at room temperature. After removal of solvent under reduced pressure, the residue was partitioned between 75 ml ethyl acetate and 25 ml water, and the aqueous layer separated. The aqueous layer was acidified with 3N hydrochloric acid, and the layer shaken again. The aqueous layer was further extracted with 25 ml ethyl acetate. The combined organic extracts were washed with brine, dried (MgSO 4 ), the drying agent removed by filtration, and the solvent removed on a rotary evaporator. The residue was chromatographed on silica gel using ethyl acetate as eluent. After removal of solvent, the product was crystallized from 3:1 ethyl acetate/hexane to yield 945 mg, m.p. 100°-100.5° C.
Analysis for C 29 H 36 O 8 (MW=512.61):
Calcd.: C, 67.95; H, 7.08.
Found: C, 68.00; H, 7.11.
EXAMPLE 17 ##STR29##
A mixture of 611 mg (1.19 mmol) of the title product of Example 16, 0.72 ml of 50% aqueous sodium hydroxide, and 11.7 ml of water was stirred at reflux. After one hour, another 2 ml of water was added and the reaction mixture was heated for an additional 2 hours. The mixture was allowed to cool and then partitioned between 75 ml of ethyl acetate and 50 ml of 3N hydrochloric acid. The aqueous layer was further extracted twice with 25 ml aliquots of ethyl acetate. The combined organic extracts were washed with water, with brine, dried over magnesium sulfate, filtered, and solvent removed on a rotary evaporator to give 501 mg of title product, m.p. 161.5°-162° C.
Analysis for C 27 H 32 O 8 (MW=484.55):
Calcd.: C, 66.92; H, 6.66.
Found: C, 67.10; H, 6.70.
EXAMPLE 18 ##STR30##
A mixture of 378 mg (1.00 mmol) of the title product of Example 2, 190 mg (1.1 mmol) of benzyl bromide, and 290 mg (2.10 mmol) of anhydrous potassium carbonate in 10 ml of dimethylformamide was stirred at room temperature for 60 hours. The solvent was removed under reduced pressure, and the residue was partitioned between ethyl acetate and 3N hydrochloric acid. The aqueous layer was extracted with ethyl acetate. The combined organic extracts were dried over magnesium sulfate, the drying agent removed by filtration, and the solvent removed under reduced pressure. After flash chromatography on silica gel using 40% by volume of ethyl acetate/hexane as eluent, there was obtained 0.43 g of the title product as an oil.
1 H NMR (CDCl 3 ): δ7.69(d, 1H); 7.40(br s, 5H); 6.59 (d, 1H); 5.11(s, 2H); 3.65(s, 6H); 2.64(br s, 2H); and 0.94(t, 3H).
Analysis for C 27 H 32 O 7 (MW=468.55):
Calcd.: C, 69.21; H, 6.88.
Found: C, 69.17; H, 6.91
EXAMPLE 19 ##STR31##
The title compound (660 mg), isolated as the 1/4 hydrate, was prepared by the method of Example 18 substituting the title product (380 mg, 1.43 mmol) of Example 13 for benzyl bromide.
1 H NMR (CDCl 3 ): δ7.70(d, 1H); 6.99(d, 2H); 6.79(d, 2H); 6.54 (d, 1H); 4.19(t, 2H); 4.13(t, 2H); 3.63(s, 6H); 2.64(br s, 2H); 2.25(s, 3H); and 0.91(t, 3H).
Analysis for C 31 H 38 O 10 .1/4H 2 O (MW=570.64):
Calcd.: C, 64.72; H, 6.75.
Found: C, 64.69; H, 6.84.
EXAMPLE 20 ##STR32##
The title product of Example 19 (500 mg, 0.876 mmol) was stirred in 14 ml of methanol containing 0.85 ml of a 50% aqueous solution of sodium hydroxide for one hour. The mixture was partitioned between 40 ml of ethyl acetate and 30 ml of 3N hydrochloric acid, and the aqueous layer further extracted twice with 20 ml aliquots of ethyl acetate. The combined organic extracts were washed with brine, dried over magnesium sulfate (MgSO 4 ), the drying agent removed by filtration, and the solvent removed on a rotary evaporator. Crystallization of the residue from diethyl ether gave the title product (321 mg), m.p. 160°-166° C.
Analysis for C 27 H 32 O 9 (MW=500.55):
Calcd.: C, 64.78; H, 6.44.
Found: C, 64.59; H, 6.84.
EXAMPLE 21 ##STR33##
The title compound (620 mg) was prepared by the method of Example 18 substituting the title product of Example 1 (512 mg) for the title product of Example 2, and substituting the title product of Example 3 (355 mg) for benzyl bromide.
1 H NMR (CDCl 3 ): δ7.70(d, 1H); 7.20(d, 2H); 6.79(d, 2H); 6.54 (d, 1H); 4.09(q, (4H); 2.64(br s, 2H); 1.23(t, 6H); and 0.91(t, 3H).
EXAMPLE 22 ##STR34##
The title compound (510 mg), m.p. 133°-134° C., was prepared by the method of Example 20 substituting the title product of Example 21 (620 mg) instead of the title product of Example 19, and carrying out the reaction for one hour at reflux instead of for two hours at room temperature.
Analysis for C 27 H 31 ClO 8 (MW=519.00):
Calcd.: C, 62.49; H, 6.02; Cl, 6.83.
Found: C, 62.42; H, 5.81; Cl, 7.78.
EXAMPLE 23 ##STR35##
The title compound (569 mg) was prepared by the method of Example 19 substituting the 406 mg of title product of Example 1 for the title product of Example 2, and further substituting the 299 mg of title product of Example 4 for benzyl bromide.
1 H NMR (CDCl 3 ): δ7.78-6.96(m, 7H); 7.70(d, 1H); 6.56(d, 1H); 4.09 (q, 4H); 2.64(br s, 2H); 1.23(t, 6H); and 0.93(t, 3H).
EXAMPLE 24 ##STR36##
The title compound was prepared by the method of Example 22 substituting 539 mg of the title product of Example 23 for the title product of Example 21. Crystallization from 5:1 ethyl acetate:hexane yielded 303 mg, m.p. 157.5°-158° C.
Analysis for C 31 H 34 O 8 (MW=534.61):
Calcd.: C, 69.64; H, 6.41.
Found: C, 69.49; H, 6.25.
EXAMPLE 25 ##STR37##
The title compound, 102 mg, m.p. 202°-205° C., was prepared by the method of Example 22 substituting the title product of Example 18 (455 mg) for the title product of Example 21, and utilizing methylene chloride as the extraction solvent instead of ethyl acetate.
Analysis for C 25 H 28 O 7 (MW=440.50):
Calcd.: C, 68.17; H, 6.41.
Found: C, 67.83; H, 6.25.
EXAMPLE 26 ##STR38##
The title compound (500 mg) was prepared by the method of Example 16 substituting the title product of Example 15 (364 mg) for the title product of Example 2.
1 H NMR (CDCl 3 ): δ7.74(d, J=8 Hz, 1H); 7.36-6.78(m, 5H); 6.53 (dd, J=8 Hz, 1H); 6.34(d, J=2 Hz, 1H); 4.09(q, 4H); 2.64(br s, 2H); and 1.23(t, 6H).
EXAMPLE 27 ##STR39##
The title compound was prepared by the method of Example 22 substituting the title product of Example 26 for the title product of Example 21. Crystallization from 60% by volume ethyl acetate/hexane yielded 219 mg, m.p. 132.5°-133° C.
Analysis for C 24 H 26 O 8 (MW=442.47):
Calcd.: C, 65.15; H, 5.92.
Found: C, 64.86; H, 5.77.
EXAMPLE 28 ##STR40##
The title compound (549 mg) was prepared by the method of Example 18 substituting the title product of Example 1 (406 mg) for the title product of Example 2, and further substituting the title product of Example 5 (299 mg) for benzylbromide.
1 H NMR (CDCl 3 ): δ8.28-6.71(m, 7H); 7.70(d, 1H); 6.56(d, 1H); 4.09(q, 4H); 2.63(br s, 2H); 1.23(t, 6H); and 0.93(t, 3H).
EXAMPLE 29 ##STR41##
The title compound was prepared by the method of Example 22 substituting the title product of Example 28 (549 mg) for the title product of Example 21 to give, after crystallization from ethyl acetate, 141 mg, m.p. 164°-167° C.
Analysis for C 31 H 34 O 8 (MW=534.61):
Calcd.: C, 69.64; H, 6.41.
Found: C, 69.64; H, 6.47.
EXAMPLE 30 ##STR42##
The title compound (370 mg) was prepared by the method of Example 18 substituting 266 mg of the title product of Example 1 for the title product of Example 2, and further substituting 211 mg of the title product of Example 6 for benzyl bromide.
EXAMPLE 31 ##STR43##
The title compound, isolated as the hemihydrate, was prepared by the method of example 22 substituting the title product of Example 30 (370 mg) for the title product of Example 21 to give, after trituration with methylene chloride, 174 mg, m.p. 136.5°-137° C.
Analysis for C 27 H 30 Cl 2 O 8 .1/2H 2 O (MW=562.45):
Calcd.: C, 57.65; H, 5.56; Cl, 12.61.
Found: C, 57.62; H, 5.66; Cl, 12.77.
EXAMPLE 32 ##STR44##
The title product (440 mg) was prepared by the method of Example 18, substituting the title product of Example 1 (406 mg) for the title product of Example 2, and further substituting the title product of Example 7 (353 mg) for benzyl bromide.
1 H NMR (CDCl 3 ): δ7.69(d, 1H); 7.35(d, 2H); 6.74(d, 2H): 6.54 (d, 1H); 4.09(q, 4H); 2.64(br s, 2H); 1.23(t, 6H); and 0.91(t, 3H).
EXAMPLE 33 ##STR45##
The title product, isolated as the hydrate, was prepared by the method of Example 22 substituting the title product of Example 32 for the title product of Example 21 to give, after crystallization from ethyl acetate/hexane, 278 mg, m.p. 136°-136.5° C.
Analysis for C 27 H 31 BrO 8 .H 2 O (MW=581.45):
Calcd.: C, 57.35; H, 5.54; Br, 14.60.
Found: C, 57.42; H, 5.54; Br, 14.70.
EXAMPLE 34 ##STR46##
The title compound (525 mg) was prepared by the method of Example 18 substituting the title product of Example 1 (406 mg) for the title product of Example 2, and further substituting the title product of Example 8 (360 mg) for benzyl bromide.
1 H NMR (CDCl 3 ): δ8.21(m, 2H); 7.70(d, 1H); 7.59(m, 2H): 743(d, 1H); 6.71(d, 1H); 6.56(d, 1H): 4.09(q, 4H): 2.63(br s, 2H); 1.23(t, 6H); and 0.91(t, 3H).
EXAMPLE 35 ##STR47##
The title compound was prepared by the method of Example 22 substituting the title product of Example 34 (515 mg) for the title product of Example 21 to give, after trituration with diethylether, 325 mg as a solid, m.p. 170.5°-171° C.
Analysis for C 31 H 33 ClO 8 (MW=569.06):
Calcd.: C, 65.42; H, 5.84; Cl, 6.23.
Found: C, 65.31; H, 5.77; Cl, 6.22.
EXAMPLE 36 ##STR48##
The title compound (497 mg) was prepared by the method of Example 18 substituting the product of Example 1 (406 mg) for the product of Example 2, and further substituting the product of Example 9 for benzyl bromide.
1 H NMR (CDCl 3 ): δ7.70(d, 1H); 7.48-6.90(m, 3H); 6.54(d, 1H); 4.09(q, 4H); 2.63(br s, 2H); 1.23(t, 6H); and 0.90(t, 3H).
EXAMPLE 37 ##STR49##
The title compound was prepared by the method of Example 22 except that the title product of Example 36 (487 mg) was substituted for the title product of Example 21. Trituration with diethyl ether produced 267 mg of the titled compound as a solid, m.p. 129°-129.5° C.
Analysis for C 28 H 31 F 3 O 8 (MW=552.55):
Calcd.: C, 60.86; H, 5.66.
Found: C, 60.74; H, 5.56.
EXAMPLE 38 ##STR50##
The title product (470 mg) was prepared by the method of Example 18 substituting 406 mg of the product of Example 1 for the product of Example 2, and further substituting 312 mg of the title product of Example 10 for benzyl bromide.
1 H NMR (CDCl 3 ): δ8.16(d, 2H); 7.70(d, 1H); 6.94 (d, 2H); 6.54(d, 1H); 4.09(q, 4H); 2.65(br s, 2H); 1.24(t, 6H); and 0.91(t, 3H).
EXAMPLE 39 ##STR51##
The title compound was prepared by the method of Example 22 substituting the title product of Example 38 (110 mg) for the title product of Example 21. Trituration with ethyl acetate/hexane produced 46 mg of the titled compound as a solid, m.p. 171.5°-172° C.
Analysis for C 27 H 31 NO 10 (MW=529.55):
Calcd.: C, 61.23; H, 5.90; N, 2.65.
Found: C, 60.97; H, 5.78; N, 2.39.
EXAMPLE 40 ##STR52##
The title compound (471 mg) was prepared by the method of Example 18 except that the title product of Example 1 (406 mg) was used instead of the title product of Example 2, and the title product of Example 11 (308 mg) was used instead of benzyl bromide.
1 H NMR (CDCl 3 ): δ7.70(d, 1H); 7.16-6.69(m, 4H); 6.55(d, 1H); 4.09(q, 4H); 2.63(br s, 2H); 1.21(t, 6H); and 0.90(t, 6H).
EXAMPLE 41 ##STR53##
The title compound was prepared by the method of Example 22 substituting the title product of Example 40 (446 mg) for the title product of Example 21. Crystallization from ethyl acetate/hexane produced 252 mg as a solid, m.p. 163°-165° C.
Analysis for C 30 H 38 O 8 (MW=526.63):
Calcd.: C, 68.42; H, 7.27.
Found: C, 68.06; H, 7.18.
EXAMPLE 42 ##STR54##
The title compound (460 mg) was prepared by the method of Example 18 substituting the title product of Example 1 (406 mg) for the title product of Example 2, and further substituting the title product of Example 12 (323 mg) for benzyl bromide. Crystallization from ethyl acetate gives the analytically pure title compound, m.p. 87.5°-88° C.
Analysis for C 35 H 46 O 8 (MW=594.75):
Calcd.: C, 70.68; H, 7.80.
Found: C, 70.72; H, 7.94.
1 H NMR (CDCl 3 ): δ7.69(d, 1H); 7.00(dd, 1H); 6.63(d, 1H); 6.60(d, 1H); 6.54(d, 1H); 4.09(q, 4H); 2.64(br s, 2H); 1.24(t, 6H); and 0.91(t, 3H).
EXAMPLE 43 ##STR55##
The title compound was prepared by the method of Example 22 substituting the title product of Example 42 (445 mg) for the title product of Example 21. Trituration with ethyl acetate produced 317 mg of the titled compound as a solid, m.p. 126.5°-127.5° C.
Analysis for C 31 H 38 O 8 (MW=538.64):
Calcd.: C, 69.12; H, 7.11.
Found: C, 69.14; H, 7.24.
EXAMPLE 44 ##STR56##
The title product of Example 1 (4.19 g, 10.3 mmol) was dissolved in 50 ml of acetic acid, and then hydrogenated at 70° C. using 60 psi of hydrogen and 10% palladium on carbon as catalyst. After eight hours, the mixture was allowed to cool, and insolubles were removed by filtration. The filtrate was concentrated under reduced pressure. The residue was chromatographed on silicagel column. Elution with 20% ethyl acetate/hexane afforded the title compound (0.80 g).
1 H NMR (CDCl 3 ): δ6.67(d, 1H); 6.27(d, 1H); 5.47(br s, 1H); 4.10(q, 4H); 2.82-2.23(m, 8H); 2.10-1.40(m, 8H); 1.20(t, 6H); and 0.92(t, 3H).
IR: One carboxyl absorption at 1718 cm -1 .
EXAMPLE 45 ##STR57##
A mixture of 250 mg (0.515 mmol) of the titled product of Example 17, 153 mg (2.06 mmol) of glycidol, and 9 mg of a 40% solution of benzyl-trimethylammonium hydroxide in methanol in 2.5 ml of dimethyl formamide under argon was stirred overnight at 70° C. After addition of another 153 mg of glycidol and one drop of 40% methanolic benzyltrimethylammonium hydroxide, the temperature was raised to 85°-90° C. with stirring. After stirring for 7 hours, the mixture was permitted to cool and was then partitioned between ethyl acetate and water. The aqueous layer was further extracted twice with ethyl acetate. The combined organic extracts were washed with brine, dried (Na 2 SO 4 ), the drying agent removed by filtration, and the solvent removed on a rotary evaporator. The residue was chromatographed on a silica gel column. Elution with 10% methanol/2.5% acetic acid/87.5% ethyl acetate as eluent afforded, after drying under vacuum for eight hours, the title product (170 mg), which was isolated as the hemihydrate.
Analysis for C 33 H 44 O 12 .1/2H 2 O (MW=641.72):
Calcd.: C, 61.77; H, 7.07.
Found: C, 61.73; H, 6.99.
EXAMPLE 46 ##STR58##
A mixture of 500 mg (0.928 mmol) of the titled product of Example 43 and 0.5 ml of thionyl chloride in 10 ml of benzene was stirred at reflux at 1.5 hours. The mixture was allowed to cool, and the solvent was removed under reduced pressure. The residue was dissolved in 4 ml of methylene chloride (CH 2 Cl 2 ), a solution of 1.19 g (4.38 mmol) of 1,3-dibenzyloxy-2-propanol in 2 ml of methylene chloride and 2 ml of pyridine was added, and the mixture was stirred at room temperature for three days. To the mixture was added 50 ml of diethyl ether, and the resulting mixture washed successively with dilute hydrochloric acid, with water, and with brine. The solution was dried over magnesium sulfate, the drying agent removed by filtration, and the solvent was removed on a rotary evaporator. Chromatography over a silica gel column using a solvent gradient of 20% increasing to 50% of ethyl acetate/hexane gave 373 mg of the title compound.
Analysis for C 65 H 74 O 12 (MW=1047.31):
Calcd.: C, 74.57; H, 7.12.
Found: C, 74.51; H, 7.19.
1 H NMR (CDCl 3 ): δ7.71(d, 1H); 7.28(m, 20H); 7.04(dd, 1H); 6.69(d, 1H); 6.63(d, 1H); 6.56(d, 1H); 5.18(quintet, 2H); 4.49(s, 8H); 4.22(t, 2H); 4.13 (t, 2H); 3.60(d, 8H); 2.73(br s, 2H); 2.62(m, 4H); 2.53(t, 2H); 2.28(quintet, 2H): 2.04(t, 4H); 1.75(m, 4H); 1.48(m, 2H); and 0.89(t, 3H).
EXAMPLE 47 ##STR59##
The titled product of Example 46 (0.258 g, 0.246 mmol) was dissolved in 25 ml of tetrahydrofuran, and then hydrogenated at room temperature using hydrogen at atmospheric pressure and 10% palladium on carbon (Pd/C) as catalyst. The insolubles were removed by filtration, and the solvent removed under reduced pressure. The residue was chromatographed on silica gel column. Elution with 5% methanol/ethyl acetate afforded 125 mg of the title compound.
Analysis for C 37 H 50 O 12 (MW=686.80):
Calcd.: C, 64.71; H, 7.35.
Found: C, 64.35; H, 7.41.
EXAMPLE 48 ##STR60##
A solution of 363 mg (0.62 mmol) of the title product of Example 38 in 45 ml of ethanol was treated with 36 mg of Raney nickel and then hydrogenated at atmospheric pressure and room temperature for 3.25 hr. The reaction mixture was filtered and the solvent was removed under reduced pressure. Chromatography of the residue over silica gel using 50--50 ethyl acetate/hexane as eluent gave the title compound as a white solid, m.p. 125.5°-127° C.
Analysis for C 31 H 41 O 8 (MW=555.68):
Calcd.: C, 67.00; H, 7.44; N, 2.52.
Found: C, 67.43; H, 7.29; N, 2.09.
EXAMPLE 49 ##STR61##
A mixture of 500 mg (0.928 mmol) of the titled product of Example 43 and 1 ml of thionyl chloride was stirred at reflux for 1.5 hours. The mixture was permitted to cool, and the volatile components removed under reduced pressure. The residue was dissolved in benzene, and 1 ml of diethylamine was added. After stirring for 2 hours, the reaction mixture was washed with 3N hydrochloric acid and with water. The solution was dried (MgSO 4 ), the drying agent removed by filtration, and solvent removed on a rotary evaporator. The residue was chromatographed on a silica gel column. Elution with 5% methanol/methylene chloride gave the titled compound (214 mg) as an oil.
Analysis for C 39 H 56 N 2 O 6 (MW=648.89):
Calcd.: C, 72.18; H, 8.70; N, 4.32.
Found: C, 72.29; H, 8.85; N, 4.26.
EXAMPLE 50 ##STR62##
To a solution of the titled product of Example 43 (676 mg, 1.25 mmol) in 5 ml of dimethylformamide (DMF) was added 190 mg (1.25 mmol) of 1,8-diazabicyclo (5.4.0) undec-7-ene followed by 585 mg (3.75 mmol) of iodoethane. After stirring overnight at room temperature, the solvent was removed under reduced pressure. The residue was dissolved in CH 2 Cl 2 . The solution was then washed with 3N hydrochloric acid, dried (Na 2 SO 4 ), filtered, and the solvent removed on a rotary evaporator. The residue was chromatographed on a silica gel column. Elution with 35% ethyl acetate/61.5% hexane/2.5% acetic acid as eluent produced the title product which was crystallized from 3:1 hexane:ethyl acetate to give 183 mg, m.p. 83.5°-84.5° C.
Analysis for C 33 H 42 O 8 (MW=566.70):
Calcd.: C, 69.95; H, 7.47.
Found: C, 69.83; H, 7.58.
EXAMPLE 51 ##STR63##
A mixture of 500 mg (1.20 mmol) of the title amide-ester of Example 2, 483 mg (1.8 mmol) of the title product of Example 12, and 348 mg (2.52 mmol) of anhydrous potassium carbonate in 12 ml of dimethylformamide was stirred at 90° C. (oil bath) for three hours. The mixture was permitted to cool, and the solvent was removed under reduced pressure. The residue was partitioned between ethyl acetate and water, and the aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were washed with brine, dried over sodium sulfate, filtered, and the solvent removed under reduced pressure. Chromatography of the residue over silica gel, using methanol-methylene chloride as eluent, gave a solid which was triturated with diethyl ether to give the title compound (468 mg), m.p. 106°-107° C.
Analysis for C 36 H 47 NO 7 (MW=605.78):
Calcd.: C, 71.38; H, 7.82; N, 2.31.
Found: C, 71.36; H, 8.00; N, 2.29.
EXAMPLE 52 ##STR64##
To a solution of 240 mg (0.40 mmol) of the title product of Example 51 in 4 ml of methanol was added 0.15 ml of a 50% aqueous solution of sodium hydroxide and 1 ml of water. The mixture was stirred for 1 hour at reflux and then permitted to cool. The cooled reaction mixture was partitioned between ethyl acetate and 3N hydrochloric acid, and the aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were washed with brine, dried over sodium sulfate, filtered, and the solvent removed under reduced pressure. Chromatography of the residue over silica gel, using methanol/ethyl acetate/acetic acid as eluent, gave a glass which was triturated with diethyl ether to give the title compound (61 mg) as a solid, m.p. 160°-164° C.
Analysis for C 35 H 45 NO 7 (MW=591.75):
Calcd.: C, 71.04; H, 7.66; N, 2.37.
Found: C, 70.60; H, 7.65; N, 2.29.
EXAMPLE 53 ##STR65##
To a stirred solution of 78 mg (2.1 mmol) of NaBH 4 in 2 ml of water at 0° C. is added over 3 minutes a solution of 250 mg (0.515 mmol) of the title product of Example 17 in 3 ml of tetrahydrofuran (THF). After 30 minutes at 0° C., the mixture was permitted to warm to room temperature, and a further 2 ml each of water and of THF were added. After one hour, the reaction mixture was acidified with 3N hydrochloric acid, and the mixture was extracted with three portions of ethyl acetate. The combined organic extracts were washed with brine, dried (Na 2 SO 4 ), the drying agent removed by filtration, and the solvent removed under reduced pressure. Crystallization of the residue from 50% ethyl acetate/hexane gave the title compound (150 mg), m.p. 131.5°-132.5° C.
Analysis for C 27 H 34 O 8 (MW=486.57):
Calcd.: C, 66.65; H, 7.04.
Found: C, 66.78; H, 6.64.
EXAMPLE 54 ##STR66##
To a stirred suspension of 319 mg (8.40 mmol) of LiAlH 4 in 12 ml of tetrahydrofuran (THF) at 0° C. was added a solution of 1.00 g (1.68 mmol) of the title product of Example 42 in 5 ml of tetrahydrofuran. After one-half hour, the mixture was permitted to warm to room temperature, and stirred further for two hours. The reaction was then quenched by sequentially adding 320 μl of water, 320 μl of 15% aqueous sodium hydroxide, and 960 μl of water. The formed salts were removed by filtration, and the solvent removed under reduced pressure to give the title compound (770 mg) as a white solid, m.p. 123°-123.5° C.
Analysis for C 31 H 44 O 6 (MW=512.69):
Calcd.: C, 72.62; H, 8.65.
Found: C, 72.59; H, 8.79.
EXAMPLE 55 ##STR67##
A mixture of 370 mg (0.941 mmol) of the title product of Example 44, 243 mg (1.13 mmol) of 1-bromo-3-phenoxypropane, and 273 mg (1.98 mmol) of anhydrous potassium carbonate in 10 ml of dimethylformamide was stirred overnight at room temperature. Thereafter, the solvent was removed under reduced pressure, and the residue was partitioned between ethyl acetate and water. The aqueous layer was separated, acidified with 3N hydrochloric acid, and the layers reshaken. The aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were dried over magnesium sulfate, and the solvent was removed under reduced pressure. The title compound (185 mg) was obtained after chromatography on silica gel using 20% ethyl acetate/hexane as eluent.
Analysis for C 31 H 42 O 7 (MW=526.68):
Calcd.: C, 70.69; H, 8.04.
Found: C, 70.67; H, 7.95.
EXAMPLE 56 ##STR68##
The title compound (118 mg), m.p. 130.5°-132.5° C., was prepared by the method of Example 22 substituting the title product of Example 55 (140 mg) for the title product of Example 21.
Analysis for C 27 H 34 O 7 (MW=470.57):
Calcd.: C, 68.91; H, 7.28.
Found: C, 68.54; H, 7.15.
EXAMPLE 57 ##STR69##
The title compound was prepared according to the method disclosed in J. Am. Chem. Soc., 1948, 70, 4187.
EXAMPLE 58 ##STR70##
A mixture of 1.48 g (10 mmol) of 5,6,7,8-tetrahydro-1-naphthol, 0.34 g (1.0 mmol) of tetra-n-butylammonium hydrogen sulfate, 6.27 g (30 mmol) of the title product of Example 57, 20 ml of methylene chloride, 9 ml of water, and 11 ml of 1N sodium hydroxide was stirred vigorously overnight at reflux. The organic layer was separated, and the solvent removed under reduced pressure. The residue was triturated with diethyl ether and filtered to remove the insolubles. The ether solution was sequentially washed with two portions of dilute aqueous sodium hydroxide, with water, and then with brine. After drying over magnesium sulfate, the solution was filtered and the solvent was removed under reduced pressure. Chromatography of the residue on silica gel, using 5% ethyl acetate/hexane as eluent gave 730 mg of the title compound.
1 H NMR (CDCl 3 ): δ7.01(dd, J=7 Hz, J=7 Hz, 1H); 6.66(d, J=7 Hz, 1H); 6.64(d, J=7 Hz, 1H); 4.73(br s, 1H); 4.20-3.38(m, 6H); 2.69(m, 4H); and 1.90-1.45(m, 10H).
EXAMPLE 59 ##STR71##
A solution of 700 mg (2.54 mmol) of the title product of Example 58 in a mixture of 9 ml of acetic acid, 3 ml of tetrahydrofuran, and 3 ml of water was stirred at 85°-90° C. After 3.5 hours, 4 drops of concentrated sulfuric acid were added and stirring continued for an additional one-half hour. The mixture was permitted to cool, and 4 g of sodium carbonate monohydrate was added. The resulting mixture was partitioned between diethyl ether and water. The organic layer was washed repeatedly with saturated aqueous sodium bicarbonate, with water, and then with brine. The solution was dried over magnesium sulfate, the drying agent was removed by filtration, and the solvent was removed under reduced pressure. Chromatography of the residue on silica gel, using 15% ethyl acetate/toluene as eluent, gave 216 mg of the title compound.
1 H NMR (CDCl 3 ): δ7.11(dd, J=7 Hz, J=7 Hz, 1H); 6.68(d, J=7 Hz, 1H); 6.61(d, J=7 Hz, 1H); 4.04(m, 4H); 2.70(m, 4H); 1.76(m, 4H); and 1.56(s, 1H).
EXAMPLE 60 ##STR72##
A solution of 202 mg (1.05 mmol) of the title product of Example 59 in 10 ml of CH 2 Cl 2 was cooled with stirring to 0° C. and treated sequentially with 370 mg (3.70 mmol) of triethylamine and 362 mg (3.15 mmol) of methanesulfonyl chloride. After one hour, the mixture was treated with another 370 mg of triethylamine and 362 mg of methanesulfonyl chloride. After one-half hour, the mixture was washed successively with water, aqueous sodium bicarbonate solution, dilute aqueous hydrochloric acid, and water. The organic phase was dried (MgSO 4 ), filtered, and the solvent removed under reduced pressure. The residue was taken up in 10 ml of dimethylformamide. To the resulting solution was added 406 mg (1.00 mmol) of the title product of Example 1 and 290 mg (2.10 mmol) of anhydrous potassium carbonate. The mixture was stirred overnight at room temperature. Another 290 mg of potassium carbonate was then added, and stirring was continued at 60° C. for six hours. The mixture was allowed to cool, and the solvent was removed under reduced pressure. The residue was partitioned between ethyl acetate and water. The aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were washed successively with water and with brine, dried (Na 2 SO 4 ), filtered, and the solvent removed under reduced pressure. The residue was chromatographed over silica gel. Elution with 15% ethyl acetate/toluene produced 152 mg of the title compound as a solid.
1 H NMR (CDCl 3 ): δ7.71(d, 1H); 7.04(d, 1H); 6.73(d, 1H); 6.70 (d, 1H); 6.59(d, 1H); 4.34(m, 4H); 4.10(q, 4H); 2.85-1.43(m, 22H); 1.24 (t, 6H); and 0.90(t, 3H).
EXAMPLE 61 ##STR73##
A mixture of 150 mg (0.277 mmol) of the titled product of Example 60, 3 ml of methanol, and 3 ml of 1N sodium hydroxide was stirred at reflux for one hour. The reaction mixture was permitted to cool and then partitioned between ethyl acetate and 3N hydrochloric acid. The aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were washed with brine, dried (MgSO 4 ), filtered, and the solvent removed under reduced pressure. Crystallization of the residue from ethyl acetate gave 24 mg of the title compound as a solid, m.p. 159.5°-161.5° C.
Analysis for C 30 H 36 O 8 (MW=524.62):
Calcd.: C, 68.68; H, 6.92.
Found: C, 68.43; H, 6.96.
EXAMPLE 62 ##STR74##
The title compound was prepared by the method disclosed in J. Org. Chem., 19, 1054 (1954).
EXAMPLE 63 ##STR75##
To a solution of 16.0 g (158 mmol) of diisopropylamine in 150 ml of tetrahydrofuran at 0° C. was added 158 ml of a 1.0M solution of n-butyllithium in hexane. The reaction mixture was cooled to -30° C., and to it was added a solution of 20.2 g (144 mmol) of the title product of Example 62 in 75 ml of tetrahydrofuran. After 1.0 hour at -30° C., the mixture was cooled to -70° C. To the resulting mixture was then added 26.1 g of allyl bromide in 38 ml of tetrahydrofuran. After 10 minutes, the mixture was permitted to warm to room temperature, and after 2 hours, it was poured into brine. The aqueous layer was further extracted with diethyl ether. After drying the combined extracts over sodium sulfate followed by filtration, the solvent was removed and the residue distilled to give a crude product (8.53 g) which was used without further purification. A solution of 4.14 g of the crude material in 13 ml of tetrahydrofuran was added to a mixture of 2.57 g of diisopropylamine, 25.4 ml of a 1.0M solution of n-butyllithium in hexane, and 25 ml of tetrahydrofuran at -30° C. The resulting mixture was kept for one hour at -30° C., and thereafter 3.0 g of allyl bromide was added. After stirring overnight at room temperature, the mixture was poured into brine, the aqueous layer extracted with diethyl ether, and the combined organic solutions dried over sodium sulfate. After filtration, the solvent was removed, and the residue was then stirred overnight in a mixture of 50 ml of diethyl ether and 50 ml of 3N hydrochloric acid. The mixture was then poured into brine and the aqueous layer was further extracted with diethyl ether. The combined organic extracts were dried over magnesium sulfate, and filtered. The solvents were removed by distillation through a Vigreaux column at atmospheric pressure. Distillation of the residue at 5 mm of pressure gave the title compound (719 mg), suitable for use in the next reaction step.
H NMR (CDCl 3 ): δ6.05-4.83(m, 6H); and 2.68-2.05(m, 8H).
IR (CHCl 3 ) 1715 cm -1 , 1642 cm -1 .
EXAMPLE 64 ##STR76##
A mixture of 719 mg (5.21 mmol) of the title product of Example 63, 970 mg (5.00 mmol) of 2,4-dihydroxy-3-propylacetophenone, 360 mg (5.00 mmol) of pyrrolidine, and 5.5 ml of toluene containing 2.0 g of 3A molecular sieves was stirred at reflux for six hours, then kept overnight at room temperature, the solution was then decanted from the sieves, and the sieves were washed with methylene chloride. The solvent was then removed under reduced pressure. Chromatography of the residue over silica gel, using 14:5:1 methylene chloride:hexane:ethylacetate as eluent, gave the title compound (439 mg) as a solid.
Analysis for C 20 H 20 O 3 (MW=314.43):
Calcd.: C, 76.40; H, 8.34.
Found: C, 76.31; H, 8.47.
EXAMPLE 65 ##STR77##
A solution of 366 mg (1.17 mmol) of the title product of Example 64 and 695 mg (2.04 mmol) of the title product of Example 12 in 11 ml of dry dimethylforamide was treated with 338 mg (2.45 mmol) of anhydrous potassium carbonate. The mixture was stirred for 2 hours at 80° C., then permitted to cool. The solvent was removed under reduced pressure, and the residue was partitioned between ethyl acetate and water. The aqueous layer was extracted with a fresh portion of ethyl acetate. The combined organic extracts were washed with brine, dried over magnesium sulfate, filtered, and the solvent evaporated. The residue was chromatographed over silica gel to give 503 mg of the title compound.
1 H NMR (CDCl 3 ): δ7.70(d, 1H); 7.01(dd, 1H); 6.64(d, 1H); 6.58(d, 1H); 6.54(d, 1H); 6.01-4.81(m, 6H); 4.20(t, 2H); 4.13(t, 2H); 2.80-1.23 (m, 24H); and 0.90(t, 3H).
EXAMPLE 66 ##STR78##
To a solution of 500 mg (1.00 mmol) of the title product of Example 58 in a mixture of 4.8 ml of t-butanol and 1.5 ml of tetrahydrofuran (THF) was added successively 0.5 ml of water, 288 mg (2.13 mmol) of N-methylmorpholine-N-oxide, and 0.2 ml of a 1% solution of osmium tetraoxide (OsO 4 ) in t-butanol. After 2.5 hours, the reaction mixture was directly applied to a column of silica gel. Elution of the column with 15% methanol/methylene chloride gave a crude product which was triturated with diethyl ether to give the title compound (453 mg) as a hemihydrate, m.p.=113°-115° C.
Analysis for C 33 H 46 O 8 .1/2H 2 O (MW=594.74):
Calcd.: C, 68.38; H, 8.17.
Found: C, 68.02; H, 7.93.
EXAMPLE 67 ##STR79##
To a solution of 90 mg (0.158 mmol) of the title product of Example 66 in 3.7 ml of t-butanol was added a solution of 135 mg (0.629 mmol) of sodium periodate in 1.0 ml of H 2 O. After stirring at room temperature for 2 hours, the mixture was partitioned between diethyl ether and water and the aqueous layer extracted with a fresh portion of ether. The combined organic extracts were washed with brine, dried over magnesium sulfate, filtered, and the solvent removed under reduced pressure. The residue was triturated with diethyl ether to give the title compound (61 mg), m.p. 107°-108° C.
Analysis for C 31 H 38 O 6 (MW=506.65):
Calcd.: C, 73.48; H, 7.56.
Found: C, 73.09; H, 7.76.
EXAMPLE 68 ##STR80##
To a solution of 10.7 g of diispropylamine in 100 ml of tetrahydrofuran at 0° C. was added 74.1 ml of a 1.43M solution of n-butyllithium in hexane. After 15 minutes the solution was cooled to -30° C. To the mixture was then added a solution of 13.5 g of the title product of Example 62 in 50 ml of tetrahydrofuran, and the resulting mixture was kept for 1 hour at -30° C. The mixture was then cooled to -65° C. and to it was added a solution of 19.6 g of 4-bromo-1-butene in 25 ml of tetrahydrofuran. The mixture was then permitted to warm to room temperature overnight. The mixture was poured into brine, and the aqueous layer was extracted with two portions of diethyl ether. The combined organic extracts were dried over sodium sulfate, filtered, and the solvent removed under reduced pressure. Distillation of the residue gave 10.68 g of material which was dissolved in 30 ml of tetrahydrofuran, then added to a cooled mixture (-30° C.) of 8.5 ml of diisopropylamine 42.7 ml of a 1.43M solution of n-butyllithium in hexane, and 50 ml of tetrahydrofuran. After 1 hour, the mixture was cooled to -65° C., and a solution of 11.2 g of 4-bromo-1-butene in 15 ml of tetrahydrofuran. After permitting the mixture to warm to room temperature overnight, the mixture was poured into brine, and the aqueous layer extracted with two portions of diethyl ether. The combined organic extracts were dried over magnesium sulfate, filtered, and the solvent removed in vacuo. The residue (13.8 g) was then stirred overnight in a mixture of 100 ml of diethyl ether and 100 ml of dilute hydrochloric acid. The layers were separated, and the aqueous layer was extracted with two portions of diethyl ether. The combined organic extracts were washed with brine, dried over magnesium sulfate, and filtered. The solvent was removed by distillation through a Vigreaux column at atmospheric pressure. Continued distillation gave the title compound (4.39 g), b.p. 85°-87° C. at 2.0 mm.
Analysis for C 11 H 18 O (MW=166.27):
Calcd.: C, 79.43; H, 10.91.
Found: C, 79.54; H, 11.01.
EXAMPLE 69 ##STR81##
A mixture of 3.93 g (20.2 mmol) of 2,4-dihydroxy-3-propylacetophenone, 3.36 g (20.2 mmol) of the title product of Example 68, 1.44 g (20.2 mmol) of pyrrolidine, and 23.5 ml of toluene was stirred at reflux under a water separator containing 3A molecular sieves for 5 hours. The mixture was then permitted to cool, and the solvent was removed under reduced pressure. Chromatography of the residue over silica gel using 25% ethyl acetate/hexane as eluant gave the title compound (5.85 g) as a dark red oil.
1 H NMR (CDCl 3 ): δ8.33(br s, 1H); 7.62(d, 1H); 6.53(d, 1H); 6.02-4.73(m, 6H); 2.82-1.17(m, 18H); and 0.97(t, 3H).
EXAMPLE 70 ##STR82##
To a solution of 3.0 g (9.55 mmol) of the title product of Example 69 and 4.01 g (11 mmol) of the title product of Example 12 in 56 ml of dry dimethylformamide (DMF) was added 2.77 g (20.1 mmol) of anhydrous potassium carbonate. The resulting mixture was stirred overnight at room temperature. The solvent was removed in vacuo, and the residue was partitioned between ethyl acetate and 3N hydrochloric acid. The aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were washed with water and with brine, dried over magnesium sulfate, filtered, and the solvent removed under reduced pressure. Chromatography of the residue over silica gel, using 10% ethyl acetate/hexane as eluent, gave the title compound (4.19 g) as an oil.
1 H NMR (CDCl 3 ): δ7.68(d, 1H); 7.00(dd, 1H); 6.68(d, 1H); 6.65(d, 1H); 6.53(d, 1H); 6.00-4.76(m, 6H); 4.21(t, 2H); 4.13(t, 2H); 2.83-1.23(m, 28H); and 0.93(t, 3H).
EXAMPLE 71 ##STR83##
To a solution of 1.00 g (1.99 mmol) of the title product of Example 70 in a mixture of 9.5 ml of t-butanol, 2.9 ml of tetrahydrofuran, and 0.95 ml of water was added 576 mg (4.26 mmol) of N-methylmorpholine-N-oxide followed by 0.4 ml of a 1% solution of osmium tetraoxide (OsO 4 ) in t-butanol. After 2.5 hours at room temperature, the reaction mixture was directly applied to a column of silica gel. Elution with 15% methanol/methylene chloride gave a glass which was triturated with diethyl ether to give the title compound (830 mg), m.p. 87°-88° C.
Analysis for C 35 H 50 O 8 (MW=598.78):
Calcd.: C, 70.21; H, 8.42.
Found: C, 69.95; H, 8.41.
EXAMPLE 72 ##STR84##
To a solution of 200 mg (0.350 mmol) of the title product of Example 71 in 9.8 ml of t-butanol was added with stirring a solution of 300 mg (1.40 mmol) of sodium periodate in 2.2 ml of water. After two hours, the mixture was partitioned between diethyl ether and water. The organic layer was washed with brine, dried over sodium sulfate, filtered, and the solvent removed under reduced pressure. The residue was chromatographed on a silica gel column, using ethyl acetate/hexane as eluent. Crystallization from diethyl ether/hexane gave 114 mg of the title compound, m.p. 72°-73° C.
Analysis for C 33 H 42 O 6 (MW=534.70):
Calcd.: C, 74.14; H, 7.92.
Found: C, 74.25; H, 7.94.
EXAMPLE 73 ##STR85##
To a solution of 98 mg (0.183 mmol) of the title product of Example 72 in 3.1 ml of dioxane was added a solution of 87 mg (0.89 mmol) of sulfamic acid in 0.8 ml of water. The solution was cooled in an ice bath, and a solution of 84 mg of 80% sodium chlorate in 0.8 ml of water was added. After one hour, diethyl ether was added, and the organic layer was washed five times with water, once with brine. The solution was dried over magnesium sulfate, filtered, and the solvent removed in vacuo to give the title compound (92 mg), m.p. 138°-138.5° C.
Analysis for C 33 H 42 O 8 (MW=566.70):
Calcd.: C, 69.95; H, 7.47.
Found: C, 69.93; H, 7.55.
EXAMPLE 74 ##STR86##
To a solution of 404 mg (0.708 mmol) of the title product of Example 71 in 4.4 ml of pyridine was added 0.70 ml (7.4 mmol) of acetic anhydride. After stirring overnight at room temperature, the mixture was taken up in ethyl acetate, and washed sequentially with two portions of aqueous sodium bicarbonate, water, and brine. The organic layer was dried over magnesium sulfate, filtered, and the solvent removed under reduced pressure. Chromatography of the residue over silica gel, using 40% ethyl acetate/hexane as the eluent, gave the title compound (314 mg).
Analysis for C 43 H 58 O 12 (MW=766.93):
Calcd.: C, 63.35; H, 7.62.
Found: C, 67.23; H, 7.67.
EXAMPLE 75 ##STR87##
The title compound (381 mg) was prepared by the method of Example 18 substituting the title product of Example 1 (406 mg; 1.00 mmol) for the title product of Example 2, and further substituting 1-bromooctane (232 mg; 1.20 mmol) for benzyl bromide.
1 H NMR (CDCl 3 ): δ7.69(d, 1H); 6.53(d, 1H); 4.10(q, 4H); 3.99 (t, 2H); 2.64(br s, 2H); 1.24(t, 6H); 0.95(t, 3H); and 0.90(t, 3H).
EXAMPLE 76 ##STR88##
The title compound (231 mg), m.p. 147.5°-148.5° C., was prepared by the method of Example 20 substituting the title product of Example 75 (361 mg) for the title product of Example 19 and carrying out the reaction for 1.5 hours at reflux instead of for 2 hours at room temperature.
Analysis for C 26 H 38 O 7 (MW=462.59):
Calcd.: C, 67.51; H, 8.28.
Found: C, 67.69; H, 8.48.
EXAMPLE 77 ##STR89##
To a mixture of 406 mg (1.00 mmol) of the title product of Example 1, 190 mg (1.20 mmol) of 1-decanol, and 393 mg (1.50 mmol) of triphenylphosphine in 10 ml of dimethylformamide was added 261 mg (1.50 mmol) of diethyl azodicarboxylate. After stirring overnight at room temperature, the solvent was removed under reduced pressure. Chromatography of the residue on silica gel, using 20% ethyl acetate/hexane as eluent, gave 408 mg of the title compound.
1 H NMR (CDCl 3 ): δ7.70(d, 1H); 6.51(d, 1H); 4.09(q, 4H); 3.99(t, 2H); 2.63(br s, 2H); 1.23(t, 6H); 0.94(t, 3H); and 0.88(t, 3H).
EXAMPLE 78 ##STR90##
The title compound (198 mg), m.p. 144°-146° C., was prepared by the method of Example 20 substituting the title product of Example 77 for the title product of Example 19, and carrying out the reaction for two hours at reflux instead of for two hours at room temperature.
Analysis for C 28 H 42 O 7 (MW=490.64):
Calcd.: C, 68.55; H, 8.63.
Found: C, 68.47; H, 8.66.
EXAMPLE 79 ##STR91##
The title compound (388 mg) was prepared by the method of Example 18 substituting the title product of Example 1 (406 mg; 1.00 mmol) for the title product of Example 2, and further substituting 1-bromohexane (198 mg, 1.20 mmol for benzyl bromide.
1 H NMR (CDCl 3 ): δ7.69(d, 1H); 6.51(d, 1H); 4.11(q, 4H); 3.99 (t, 2H); 2.64(br s, 2H); 1.25(t, 6H); 0.95(t, 3H); and 0.91(t, 3H).
EXAMPLE 80 ##STR92##
The title compound (168 mg) was prepared by the method of Example 20 substituting the title product of Example 79 for the title product of Example 19, and carrying out the reaction for 1 hour at reflux instead of for 2 hours at room temperature. The product was crystallized from ethyl acetate, m.p. 164.5°-165° C.
Analysis for C 24 H 34 O 7 (MW=434.54):
Calcd.: C, 66.35; H, 7.89.
Found: C, 66.10; H, 7.97.
EXAMPLE 81 ##STR93##
To a solution of 790 mg (2.01 mmol) of the title product of Example 44 in 4 ml of acetic acid was added 547 mg (4.02 mmol) of anhydrous zinc chloride. The mixture was stirred for six hours at reflux, and then permitted to cool. The mixture was partitioned between ethyl acetate and dilute hydrochloric acid. The aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were washed successively with five portions of aqueous sodium bicarbonate, water, and then brine. The extracts were dried over sodium sulfate, filtered, and the solvent removed under reduced pressure. Chromatography of the residue over silica gel using 25% ethyl acetate-hexane as eluent gave the title compound, 230 mg.
1 H NMR (CDCl 3 ): δ12.55(s, 1H); 7.29(s, 1H); 4.13(q, 4H); 2.54(s, 3H); 2.90-1.43(m, 14H); 1.25(t, 6H); 0.95(t, 3H).
EXAMPLE 82 ##STR94##
A mixture of 204 mg (0.469 mmol) of the title product of Example 81, 378 mg (1.41 mmol) of the title product of Example 12, and 136 mg (0.985 mmol) of anhydrous potassium carbonate in 4 ml of dimethylformamide was stirred at 80° for six hours. A further 136 mg of potassium carbonate was added, and the mixture was heated for another six hours. The mixture was permitted to cool and was partitioned between ethyl acetate and dilute hydrochloric acid. The aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were washed with brine, dried over sodium sulfite, filtered, and the solvent removed under reduced pressure. Chromatography of the residue over silica gel using 15% ethyl acetate/toluene as eluent gave the title compound, 114 mg.
Analysis for C 37 H 50 O 8 (MW=622.81):
Calcd.: C, 71.36; H, 8.09.
Found: C, 71.48; H, 8.08.
EXAMPLE 83 ##STR95##
A mixture of 50 mg (0.080 mmol) of the title product of Example 77, 3 ml of methanol, and 1 ml of 1N aqueous sodium hydroxide was stirred at reflux for one hour. The mixture was allowed to cool, and was partitioned between ethyl acetate and dilute hydrochloric acid. The aqueous layer was further extracted with two portions of ethyl acetate. The combined organic extracts were washed with brine, dried over magnesium sulfate, filtered, and the solvent removed under reduced pressure to give the title compound (35 mg), as an oil.
Analysis for C 33 H 42 O 8 (MW=566.70):
Calcd.: C, 69.69; H, 7.47.
Found: C, 70.28; H, 7.86.
EXAMPLE 84 ##STR96##
To a suspension of 250 mg (0.515 mmol) of the title product of Example 17 in 5 ml of water was added a solution of 71 mg (0.52 mmol) of anhydrous potassium carbonate in 5 ml of water. A 5 ml portion of methanol was added, and the resulting mixture was warmed to effect solution. The solvent was evaporated under a stream of nitrogen, and the residue was dried by azeotropic distillation with toluene to give the title compound, 269 mg, isolated as the hemihydrate.
Analysis for C 27 H 30 K 2 O 8 .1/2H 2 O (MW=569.75):
Calcd.: C, 56.91; H, 5.48.
Found: C, 56.55; H, 5.71.
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This invention relates to LTD 4 antagonists of the formula: ##STR1## or pharmaceutically acceptable salts thereof, wherein R 1 is methyl, phenyl, ##STR2## wherein X 1 and X 2 may be the same or different and are members of the group consisting of hydrogen, --Cl, --Br, --CF 3 , --NH 2 , --NO 2 , or alkyl of 1-3 carbon atoms; m is 1 to 9; n is 1 to 5; V is --CH(OH)--, or --CH 2 --; W is hydrogen or alkyl of 1-6 carbon atoms; Y is hydrogen or --COCH 3 provided that when W is hydrogen Y is not hydrogen; both Z moieties are --CHO, --COOR 2 , --COR 3 , --CH(OR 4 )--CH 2 OR 4 , or CH 2 OR 4 with the exception that when one Z moiety of Formula I is COOR 2 , the other Z moiety may be COR 3 ;
R 2 is hydrogen, a pharmaceutically acceptable cation, straight or branched chain alkyl having 1-6 carbon atoms, --CH 2 --CH(OR 5 )--CH 2 --OR 5 , CH(CH 2 OR 5 ) 2 with the proviso that when Z is --COOR 2 , the R 2 substituent in one --COOR 2 moiety may be the same or different from the R 2 substituent in the other COOR 2 moiety;
R 3 is --NR 7 R 8 wherein R 7 and R 8 may be the same or different and are members of the group comprising hydrogen or alkyl having 1-6 carbon atoms;
R 4 is hydrogen, or --C(O)--R 6 ;
R 5 is hydrogen, benzyl-, or alkyl or 1-3 carbon atoms; and
R 6 is alkyl of 1-6 carbon atoms.
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CROSS RELATION TO OTHER APPLICATION
This application is a continuation-in-part of applicant's co-pending application Ser. No. 804,918, filed 12/5/85, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to ozone generating apparatus and more particularly to a novel apparatus for producing ozone especially for the elimination of odors in enclosed spaces.
2. Discussion of the Prior Art
Ozone generating apparatus has taken on many forms in the prior art. A patent search in the United States, for example, has revealed the following U.S. patents:
______________________________________U.S. Pat. No. Inventor Issue Date______________________________________3,838,290 Crooks 9/24/743,865,733 Taylor 2/11/754,124,467 Pincon 11/7/784,156,652 Weist 5/29/79______________________________________
Generally these devices are different in structure and function, and result in comparison with the present invention. The present invention offers a durable, lightweight ozone generating apparatus with a novel construction which can economically deodorize an enclosed area.
In the parent application, cited and applied references included U.S. Pat. No. 3,352,775 issued to McNamara, U.S. Pat. No. 3,842,286 issued to Imris et al, U.S. Pat. No. 3,442,788 issued to Wooten et al, and U.S. Pat. No. 1,044,700 issued to Small et al. None of the above patents teach the use of a soda-lime glass as does the present invention.
Applicant has found through experimentation that the glass in the glass tubes for his application should be soda lime glass. Other types of glass tubes will begin clouding soon after operation of the ozone generating device and thus reducing ozone output by about a factor of 4. The above references cited are generally for applications in which space limitations are not a problem. Typically, applicant has 4 mm diameter glass tubes and the rods within adjacent tubes are spaced 4 mm apart likewise. Relative to the references, applicant's apparatus has a much greater field intensity due to a smaller glass tube radius.
The above problem was not foreseen by McNamara. If any glass tubes were used other than soda lime glass, inoperability of applicant's apparatus would result. McNamara is silent with respect to soda lime glass as the dielectric, and it would not be obvious given McNamara to use this special type of glass.
Wooten et al., Imris, Lowther or Small et al., do not disclose soda lime glass as being critical to the operation of their respective apparatus, and it would not be obvious given either of these references above or in any combination to use soda lime glass.
SUMMARY OF THE INVENTION
The present invention comprises apparatus for producing ozone, especially for the elimination of undesirable odors from enclosed spaces. The apparatus consists of at least a pair of ozonizer tubes, the tubes being open on one end and closed on the other end. The tubes are made of a dielectric material such as glass and arranged parallel to each other. The open end of one tube is aligned 180° from the open end of the paired tube. Ideally about 2 millimeters spacing is provided between tubes. Inside of the ozonizer tubes is placed a rod of a conductive material such as stainless steel which also has the advantage of being non-corrosive. The rod is placed within the tube with its tip protruding from the open end of the tube. The tube at its open end containing the rod is sealed with a silicon sealant. Sockets are provided to receive the tips of the rods extending from the tubes as the tubes are arranged parallel to each other with the tips of adjacent rods within the tubes aligned 180° from each other. A support to support the tubes is provided and is preferably made of teflon or the like. The sockets are connected to a source of voltage such as a voltage transformer which operates from AC current. Ideally 7500 volts (30 ma) is used for the voltage drop. Subjecting the rods to this high voltage drop creates an electrode from the assembled tubes and generates an electrical discharge whereby oxygen molecules from the air are converted to ozone molecules.
At this point, the above apparatus can be used in conjunction with a fan to supply a stream of air past the tubes, the end result being a stream of ozone emitted by the apparatus. The ozone can be channeled into a space containing undesirable odors such as tobacco smoke, etc., to allow the ozone to break down the molecules creating the odor and hence purify the air in the enclosed space. It should be noted that any number of pairs of ozonizer tubes in parallel can be used, a greater number of tubes generating a larger volume of ozone.
The apparatus also has an additional safety feature present which results in any excessive ozone production to be counteracted by a odor emitting chamber. The chamber is located downstream of the fan and after the ozone producing cycle is complete and the undesired odor eliminated, the chamber can emit an odor which is pleasant, a conventional air freshening odor which would react with excess ozone if present. The chamber could be operated on a timed cycle by conventional timing means to begin after ozone production ceases. A user of the device would be assured that the deodorized space does not retain a high ozone concentration after the ozone production ceases.
It is, therefore, an object of the present invention to provide apparatus for generating ozone that is economical to produce and manufacture.
Another object of the present invention is to provide apparatus for the generation of ozone which yields a consistant output due to its composition.
Another object of the present invention is to provide apparatus for generating ozone which is sealed at atmospheric pressure for greater durability and stability.
Still another object of the present invention is to provide apparatus for generating ozone which uses glass tubes and has a relatively long useful life.
Yet another object of the present invention is to provide an apparatus which generates ozone and can be used in enclosed spaces to eliminate unwanted odors safely and effectively.
Still another object of the present invention is to provide an improved ozone generating system characterized by its simplicity and efficiency.
Another object of the present invention is to provide an ozone generating apparatus for deodorizing an enclosed space which will not result in high ozone levels in that enclosed space after the operation of the apparatus.
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. This invention itself both as to its organization and manner of operation, together with further objects and advantages thereof, may be best understood by reference to the following descripton taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is an overhead view of the apparatus of the present invention showing the ozone tubes in an array.
FIG. 2 is an elevation view of the apparatus shown in FIG. 1 in accordance with the present invention.
FIG. 3 is a sectional view of the apparatus of the present invention along line A--A of FIG. 2.
FIG. 4 is a detail showing the ozone tubes in an array.
FIG. 5 is a perspective view showing a tube being fit into a socket array in accordance with the present invention.
FIG. 6A shows a rod of the present invention.
FIG. 6B shows a glass tube of the present invention.
FIG. 6C shows a rod assembled in a glass tube to form an electrode in accordance with the present invention.
FIG. 7 is a perspective view of the ozone generating apparatus of the present invention assembled in a convenient carrying case.
FIG. 8 is an elevational view of the apparatus featuring the odor-emitting chamber in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the accompanying FIGS. 1 through 7, the present invention of an ozone generating apparatus can be described. An ozone tube generally designated as 2 is shown which is comprised of a tube 4 of a dielectric material such as glass and a rod 6 of a conductive material such as steel. Preferably the tube 4 is made of a soda lime of "flint" glass and the rod 6 of stainless steel. Soda lime glass has the advantage over other glass with respect to its ability to resist becoming "fogged" or dirty during the ozone generating process. Stainless steel has the obvious advantage of allowing rod 6 to be conductive yet corrosion resistant. Tube 4 has a closed end 8 and an open end 10. Rod 6 is fit into the open end 10 of tube 4 and is housed therein during operation of the apparatus. A gap 12 exists at the closed end 8 of tube 4. This gap 12 is between the end rod 6 and the end 8 of tube 4. At the open end 10 of tube 4, the tip 14 of rod 6 is allowed to project therefrom slightly as seen best in FIG. 6C. Rod 6 fits within tube 4 and is housed therein except for the tip 14. A sealant 16 is used to seal the open end 10 of tube 4 containing rod 6. Preferably the sealant 16 is a conventional silicon sealant sealed at atmospheric pressure.
Referring to FIGS. 1 through 4, the arrangement of an array 3 of ozonizing tubes 2 is shown in a housing. The assembled ozone tubes 2 are the glass tubes 4 which contained rods 6 therein sealed with sealant 16 as shown in FIG. 6C. These assembled tubes 2 are placed in socket arrays 18a and 18b forming an array 3 of ozonizing tubes. Socket arrays 18a and 18b consist of conventional sockets in a bank or series. The tip 14 of rod 6 is placed in the appropriate socket of socket array 18a or 18b. In the embodiment of this invention the assembled ozone tubes are arranged to produce opposite polarity between adjacent tubes.
In an array 3 of tubes 2, one tube 2 will be placed with the tip 14 of rod 6 in socket array 18a. The adjacent tube 2 will be placed with the tip 14 of rod 6 in socket array 18b. This pattern is continued until the desired number of ozone tubes 2 is assembled in the socket arrays 18a and 18b as seen best in FIG. 4. Generally, the present invention needs at least two ozone tubes 2 arranged in opposite polarity as describe above. Additionally, paired ozone tubes 2 will produce an increase in the amount of ozone generated. Depending on the application, the number of ozone tubes 2 therefore will be at least two and could be increased to any desired number in pairs to continue the opposite polarity of adjacent ozone tubes 2. It should also be noted that adjacent ozone tubes 2 are parallel to each other with a gap of about 2 mm being preferable for maximum efficiency of the apparatus. Additional support for the ozone tubes 2 is provided by tube supports 20a and 20b located near the end of the ozone tube 2. The supports 20a and 20b have semi-circular cut-out portions 22a and 22b to receive the ozone tubes 2, and provide support thereto. In combination with the above described apparatus, a voltage transformer 24 is used which can take power from a power source such as 115 volt conventional outlet (not shown). The secondary terminals 26a and 26b of the voltage transformer are connected to the socket arrays 18a and 18b and consequently the rods 6 of the ozone tubes 2. A suitable voltge drop is chosen, such as 7500 volts (at 30 milliamps), and an electrostatic charge is created in the ozone tubes 2. Each tube 2 becomes an electrode and the consequent electrostatic charge will begin the process of converting oxygen surrounding the tubes 2 into ozone. The high energy of the electrostatic field causes the oxygen molecule to add another oxygen radical to form ozone.
The above described apparatus has a practical and useful application as an odor eliminator. Ozone, once formed by exciting oxygen, cannot recombine to the oxygen state by itself. The ozone molecule does this by losing one-third of its weight. It can do this easily since in an environment having odors and/or particles of organic matter the odors and/or particles are actively seeking the ozone. In combining with an organic particle, the organic matter is reduced to an inert, odorless particle. Of course, the ozone is reduced to oxygen. In combination with the above described ozone generating means, a fan 28 could be mounted in housing 5 in a conventional manner to circulate air around and past the tubes 2 as best shown in FIG. 1. The ozone generated can be then directed through outlet 29 to the desired environment by the fan 28 which would also serve to continually supply oxygen to the apparatus. Placed in an enclosure to be deodorized, this apparatus can be used to eliminate unwanted odors and will reach all the places that air would reach.
FIG. 7 shows the housing 5 of the apparatus to be a carrying case 30 which is portable. In this embodiment the carrying case 30 would include a tube cover 32 to cover the array 3 of tubes 2 within case 30. Tube cover 32 would have a handle 34 and a timer 36 with a switch 38 connected to a power outlet (not shown). The carrying case 30 would also have a lid 40, and fan 28 of FIG. 1 would be located within the case 30. This apparatus could be conveniently carried to any desired location and easily operated by setting timer 36 to a desired time and closing switch 28. The operator could then leave the space and return after the apparatus has shut itself off.
Referring to FIG. 8, an additional embodiment of the present invention can be described which contains a built in safety feature. FIG. 8 shows an array of ozonizing tubes 3 with a fan 28 upstream of the tubes 3 as also shown in FIG. 3. A voltage transformer 24 is connected to the array of ozonizing tubes 3. A chamber 42 is also present located in housing 5 of the apparatus which contains a substance which, if exposed to ozone, would deplete or breakdown ozone molecules. A typical substance such as a common perfume could be used or the like. The chamber 42 is located downstream of the fan 28 and can be sealed by a valve 44 wuch as a butterfly valve. Sealing would occur when valve 44 is in a horizontal position. When value 44 is caused to be moved to a vertical position as shown in dotted lines, the chamber 42 is open to the stream of air directed by the fan 28. The air stream would allow the perfume from chamber 42 to be released to the atmosphere surrounding the apparatus thereby depleting any residual ozone concentration after the ozone generating cycle is complete. A control timer (not shown) can be used to implement the opening and closing of valve 44. The timer would be connected to the voltage transformer 24, the fan 28 and the valve 44, and would maintain valve 44 closed when the voltage transformer and fan are operational and producing ozone. When ozone production is halted, the timer would continue operation of the fan 28 and cause the valve 44 to open thereby releasing the perfume to the atmosphere surrounding the apparatus. The timer would be a conventional device well known in the prior art, the system would then function with a "fail safe" safety feature. The fail safe system would guarantee that the environment that is to be occupied immediately after ozone treatment is free of a potential harmful concentration of residual ozone which normally can result from ozone treatments. This guarantee in the system would be present regardless of ventilation considerations and would allow the apparatus to comply with strict health compliance standards.
The invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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Apparatus for the generation of ozone by electrostatic discharge. An array of glass tubes are provided each containing a conductive rod therein serving as a core. Adjacent tubes are parallel to each other and the conductive rod of each tube is connected to the secondary terminal of a high voltage transformer. The tubes containing the conductive rods serve as an electrode when the voltage transformer is activated thereby creating an electrostatic field. Oxygen molecules in the electrostatic field are transformed to form ozone molecules. The apparatus can be applied to deodorizing an enclosed space with the addition of a fan to feed oxygen past the tube array and distribute the ozone that is generated. The apparatus also has an odor emitting chamber to prevent excess ozone build up after operation.
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FIELD OF THE INVENTION
This invention relates to the application of thermoplastic inserts in structural sandwich panels. More specifically this invention relates to a method of securing a thermoplastic insert in a structural sandwich panel which panel has two outer skins from thermoplastic material and an intermediate layer of foam or honeycomb material. This invention relates more specifically to securing a thermoplastic insert, placed in a hole in a structural sandwich panel, to the thermoplastic skins of said sandwich panel using ultrasonic welding.
This invention is especially useful in aircraft floor panels.
BACKGROUND OF THE INVENTION
Structural sandwich panels are often used in aircraft, as floor and/or bulkhead panels. Traditionally a sandwich panel consists of a pair of relatively thin skin sheets, and an intermediate layer of foam or honeycomb material. Bonded together the result is a panel with a high strength-to-weight ratio, which makes it of interest for use in aircraft. Sandwich panels are very resistant to loads that are evenly distributed over a relatively large surface area. However when sandwich panels are subjected to loads where the force is applied to a point of the panel, the intermediate layer can be crushed locally and the skins can delaminate from the core. This characteristic of sandwich panels is a problem when the panels are to be used as floor panels and therefore have to be secured to a panel support structure. The fasteners such as e.g. screws, bolts, nails, often will crush the intermediate layer locally, when passed through the panel in order to secure the panel to the support structure. Therefore it is conventional in the art of securing sandwich panels to support members, to use inserts in the panel. The inserts have a hole through which the fastener may pass in order to attach the panel to the support members e.g. rails or studs. The insert then isolates the forces exerted by the fastener which are necessary to properly attach the panels to the support member. The method of securing the insert into a hole in the sandwich panel is of direct consequence to the amount of shear and compressive forces the panel in connection to the support member is able to withstand.
The inserts used generally comprise a cylindrical body with a vertical cylindrical bore. The shape, size, and form of the vertical cylindrical bore in the body is largely dependant on the fastener which is used to secure the panel to the support members. Bolts, screws, and the like exist in various forms and measurements which will require specifically shaped vertical cylindrical bores in the insert. The shape, size and form of the body part of the insert is largely dependant on the method of securing the insert into the panel. Most inserts also comprise a cylindrical head disc which is larger in diameter than the body portion.
Because of the importance of good connection and stress relief between panel, insert, fastener and support member, various methods for securing inserts in sandwich panels have been developed and are known in the prior art.
U.S. Pat. Nos. 4,242,158 and 4,305,540 to Olson, disclose a method of securing an insert in a sandwich panel using an adhesive for one part of the insert and an anvil for forming the other part of the insert. The insert used in this method comprises a cylindrical head disc as top end of a cylindrical body. The length of the body portion is greater than the thickness of the panel. The insert is introduced in a hole in the panel with the cylindrical body, the head disc of the insert rests on top of the top skin of the panel. The bottom part of the cylindrical body of the insert protrudes below the bottom skin of the panel. The head disc of the insert is secured to the top skin of this panel using a suitable adhesive. The anvil presses against the bottom part of insert and this applied pressure causes this protruding portion to flare over and form a flange which secures the insert to the bottom skin. At the same time compressed air blows excess adhesive from the contacted surface from the insert.
Sandwich panels with thermoplastic skin sheets allow the use of thermoplastic inserts. Until now the securing of thermoplastic inserts into the sandwich panel did not satisfy the structural requirements imposed by aircraft manufacturers. This is also stated by Worthing in his U.S. Pat. No. 4,817,264, column 2, line 27-45. Worthing consequently chooses to use a two part insert. This two part insert consists of a metal flange member and a thermoplastic body portion. The method described in this patent uses an adhesive to secure the head disc to the top skin of the panel and ultrasonic energy to soften the protruding end of the insert and pressure to cause this portion to flare over and form a flange. This flange forms a mechanic connection and is similar to the flange described in U.S. Pat. Nos. 4,242,258 and 4,305,540 to Olson.
The above-mentioned methods for securing inserts in sandwich panels are laborious and time consuming. Specifically, the time necessary to allow the adhesive to sufficiently harden, largely influence the production time and costs of such sandwich panels. The minimum time for hardening is generally several hours at room temperature. Also the use of adhesives requires more handling by personnel and is more fault sensitive. Also the use of adhesives adds weight to the panel and decrease the weight-to-strength ratio.
Another drawback of the prior art is the protruding head disc and bottom flange of the insert when secured into the sandwich panel.
One of the objects of this invention is to provide a method for securing a thermoplastic insert, which is placed inside a through hole in a sandwich panel, to vertical hole walls of the thermoplastic skins of said sandwich panel. The insert for use with the new securing method comprises an essentially cylindrical body with a cylindrical through bore to receive a fastener. It is another object of the invention that ultrasonic energy be applied in order to secure the insert to the thermoplastic skins of the sandwich panel. Another object of the invention is to provide the thermoplastic insert with a concentric thermoplastic rim at the top and bottom of the body, which acts as sacrificial thermoplastic matter and is fused together with the thermoplastic material on top and bottom skins of the sandwich panel as a result of the appliance of ultrasonic energy.
It is an object of this invention to provide a method for securing a thermoplastic insert to thermoplastic skins of a sandwich panel which takes not more than 10 seconds in time and results in a watertight connection. The connection between thermoplastic insert and thermoplastic skins of the panel is made by fusing thermoplastic sacrificial matter of the insert with the thermoplastic skin by applying ultrasonic energy.
SUMMARY OF THE INVENTION
The method according to the invention, of securing a thermoplastic insert in a sandwich panel, comprises the steps of providing a sandwich panel with thermoplastic top and bottom skin sheets, drilling a through hole in said sandwich panel, providing a thermoplastic insert having integrally formed sacrificial thermoplastic material, providing an ultrasonic welding apparatus, placing said insert in said through hole, applying ultrasonic energy and pressure until said sacrificial thermoplastic material of said thermoplastic insert is fused to said thermoplastic top and bottom skin sheets of said sandwich panel forming a fused bond, cooling said fused bond before further handling said sandwich panel.
The insert for use in this method is made of the same thermoplastic material as the skin sheets of the sandwich panel. Especially the top and bottom part of the inserts are to fit snugly to the through hole edges. Preferably, the insert used with this method comprises an essentially cylindrical body with an axial through bore, which bore can receive a fastener with which the panel can be fastened to support members or the like in a structure.
The sacrificial thermoplastic material of the insert is an integral part of said insert. The sacrificial material has the form of a rim on the top and bottom plane of the insert, has a same outer diameter as the outer diameter of the body of the insert, and has a volume sufficient to fill the gap between insert and skin sheet and to form the fused bond between insert and skin sheet under influence of ultrasonic energy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a-d depicts cross-sectional views of a number of preferred embodiments of a thermoplastic insert, prior to securing.
FIG. 2 is an exploded perspective view of the assembly according to the invention.
FIG. 3 is a cross-sectional enlarged view of the insert in combination with sandwich panel, prior to securing.
FIGS. 4a-c are cross-sectional views depicting the sequential steps of securing the thermoplastic insert to the top and bottom thermoplastic skin sheets of the sandwich panel.
FIG. 5 is a cross-sectional view of a sandwich panel and thermoplastic insert secured therein in accordance with this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the present preferred embodiments of the invention.
FIGS. 1a-d depict a number of possible preferred embodiments of inserts 1 prior to assembly and securing in a hole in a sandwich panel. Insert 1 is designed specifically to enable securing with ultrasonic energy in a sandwich panel with thermoplastic skin sheets. For this reason the generic form of insert 1, according to the invention, comprises an essentially cylindrical body 12 and integrally formed axial thermoplastic sacrificial top and bottom (second and first) rims 13 and 14. The outer diameter of top and bottom sacrificial rims 13 and 14 are equal to the outer diameter of body 12 of insert 1. In the currently preferred embodiment as shown in FIG. 1a, insert 1 further comprises bore 10 with countersunk part 11. When mounting a sandwich panel which is equipped with a number of inserts according to FIG. 1a, fasteners e.g. bolts will be used, countersunk part 11 will then receive the head portion of the bolt while bore 10 will receive the shank portion. Use of inserts with a countersunk portion 11 will then after mounting of the panel on panel support members result in smooth top skin without protruding bolt heads.
As shown in FIG. 1a the cross-sectional view of rim 13 is rectangular in shape, while rim 14 further comprises a countersunk portion 22. FIG. 1b shows an embodiment of insert 1 without countersunk part 11, while rims 13 and 14 are the same as in the embodiment shown in FIG. 1a. FIG. 1c shows rim 14 in rectangular shape. In FIG. 1d an embodiment is shown with recess 19 in body 12, this embodiment is suitable for use of a combination of two securing methods e.g. ultrasonic energy and potting resin.
The method according to the invention of securing a thermoplastic insert in a sandwich panel, by fusing thermoplastic sacrificial material of the insert to the thermoplastic material of the skin sheets vertical hole walls of through hole using ultrasonic energy will now be described in general terms.
As depicted in FIG. 2 insert 1 is placed top side down on anvil 2, consequently hole 9 in top side down placed sandwich panel 4 is aligned with insert 1 and sandwich panel 4 is lowered, with top sheet 6 faced downward, on top of insert 1. Sandwich panel 4 is supported by table 3 in which anvil 2 is situated. Then horn 5 is placed on insert 1 and ultrasonic energy and pressure (of the weight of horn 5) are applied so as to form a fused bond between the thermoplastic material of top and bottom (second and first) skin sheets 6, 7 and insert 1. Anvil 2 and welding horn 5 are part of the ultrasonic welding apparatus. Welding horn 5 can be moved relatively to table 3, while anvil 2 is fixedly attached in said table 3. In the currently preferred embodiment of the invention an ultrasonic apparatus of the 900-SERIES of manufacture BRANSON ULTRASONIC CORP, Danburry, Conn. USA is used.
Hole 9 in panel 4 is drilled in such a way as to result in a hole with vertical hole walls along the respective top and bottom skin sheets 6 and 7 without delaminations of said skin sheets. In order to attain this, it is preferred to place plates of PERSPEX-glass on top and bottom skin sheets 6, 7 of panel 4 prior to drilling and consequently drill a hole through the first layer of PERSPEX, through skin sheet 6, through core layer 8, through skin sheet 7 and through the second layer of PERSPEX. After the drilling operation the PERSPEX plates are removed. Along this way through hole 9 is formed.
FIG. 3 shows a cross-sectional view of insert 1 as shown in FIG. 1a, assembled in hole 9 prior to fusing. The figure shows in exaggerated size gap 17a between insert 1 and adjacent top skin hole wall 6a, gap 17b between insert 1 and adjacent bottom skin hole wall 7a and integral sacrificial thermoplastic rims 13 and 14 of insert 1. Rims 13 and 14 must be dimensioned as to provide sufficient sacrificial thermoplastic material to fill gaps 17a and 17b and thus provide the necessary volume for the fused bond between thermoplastic skin sheets and insert. In order to attain a properly fused bond, a glove-like fit for insert 1 in hole 9 is necessary.
In the currently preferred embodiment of insert 1 rim 13 has a height of 0.25 mm and a width of 0.5 mm, and rim 14 has a height of 0.40 mm and a width of 0.50 mm. The height of skin hole wall 6a in the preferred embodiment is 0.75 mm and the height of bottom skin hole wall 7a is 0.5 mm. The glove-like fit of insert 1 in hole 9 is attained in the currently preferred embodiment by drilling hole 9 with a drill having a diameter of 0.2 mm larger than the diameter of the insert.
FIGS. 4a-4c show the steps of the method of securing the thermoplastic insert according to the preferred embodiment of the invention. FIG. 4a depicts a cross sectional view of insert 1 being assembled in accordance with the present invention. Insert 1 is turned top down, and the bore 10 with countersunk portion 11 and sacrificial rim 13 facing anvil 2 of the ultrasonic welding apparatus is aligned with head portion 18 of anvil 2. Sandwich panel 4 is also turned top down, with top skin sheet 6 facing table 3 and through hole 9 aligned with insert 1 and head portion 18 of anvil 2. Horn 5 of the ultrasonic welding apparatus is aligned with hole 9, insert 1 and anvil 2. Insert 1 is placed over head portion 18 of anvil 2, then panel 4 is placed over insert 1 as shown in FIGS. 4b and 3. Since rim 13 rests on lower part of head portion 18 of anvil 2, a part of insert 1 protrudes over skin sheet 7. The height of the protruding part is equal to the combined heights of rim 13 and rim 14. As shown in FIG. 4b, horn 5 is lowered and rests with flat, solid base 21 on top of rim 14 of insert 1. Once ultrasonic energy is applied, the energy will cause both rims 13 and 14 to soften, flow into respectively gap 17a and 17b and fuse with them also under influence of the ultrasonic energy and friction between insert and hole wall thermoplastic material of respectively top skin sheet 6 and bottom skin sheet 7.
Experiments with different forms and measures of the currently preferred embodiment of insert 1 as shown in FIG. 1a have taught a minor influence of shape and form of head portion 18 of anvil 2 on the necessary measurements of rim 13. The thermoplastic sacrificial material of rim 13 is efficiently guided into gap 17a under the influence of the specific form of head portion 18 of anvil 2. This results in a smaller necessary measurement of rim 13 in the preferred embodiment than rim 14. In effect the head portion of the ultrasonic welding apparatus can be tailor made to the shape, form and dimension of the bore and possible countersunk portion in any thermoplastic insert that is to be secured by use of ultrasonic energy to skin sheets of a sandwich panel.
In the currently preferred embodiment, insert 1 as shown in FIG. 1a comprises countersunk portion 11 in through bore 10, and anvil 2 is shaped to fit. This specifically shaped form of anvil 2 has a guiding effect on the sacrificial thermoplastic material of top rim 13 during the appliance of the ultrasonic energy. Flat, solid base 21 of horn 5 has no such guiding effect, resulting in the necessity to provide more sacrificial material in the bottom rim 14, in order to fill gap 17b and form a fused bond. It stands to reason that if the base 21 of horn 5 could also be tailor made to the shape, form and dimension of the bore of insert 1, without adversely effecting the ultrasonic wave pattern, undoubtedly the bottom rim 14 could have a smaller volume.
FIG. 4c depicts insert 1 of the preferred embodiment as shown in FIG. 1a secured in panel 4, prior to removing the ultrasonic work station formed by table 3, anvil 2 and horn 5.
FIG. 5 shows a cross sectional view of sandwich panel 4, with insert 1 secured therein. Areas 15a and 15b depict the circumferential fused bond insert and top skin sheet 6 of the panel 4. In areas 16a and 16b the fused bond is depicted between insert and bottom skin sheet 7 of the panel 4. As the thermoplastic material of the insert 1 is the same as the thermoplastic material of the skin sheets 6, 7 of the panel 4, the bond between insert 1 and skin sheets 6, 7 consists of fused thermoplastic material and no clear bond line is visible. This is shown in by indicating the thermoplastic material with continuous shading in top skin sheet 6, body 12 of insert 1 and bottom skin sheet 7, without bond lines between skin sheets 6, 7 and insert 1. It is desirable to use the same thermoplastic material for insert and skin sheets in order to get a proper fused bond. The use of fibre reinforcements is optional. For example, in the currently preferred embodiment polyetherimide (PEI)-inserts were bonded to PEI-fibre reinforced skin sheets. Also PEI-fibre reinforced inserts were bonded to PEI-fibre reinforced skin sheets. The insert can be made of PEI with 30% glass. Fused bonds between polyether-etherketone (PEEK) inserts and PEEK skin sheets, fibre reinforced PEEK skin sheets and non-fibre reinforced PEEK inserts are also possible.
It will be apparent to those skilled in the art that various modifications and variations could be made to the described invention of securing thermoplastic inserts to the thermoplastic skin sheets of a sandwich panel using ultrasonic energy, without departing from the scope or spirit of the invention.
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Method for connection of thermoplastic inserts in structural sandwich panels. This connection is realized by ultrasonic welding. According to the invention the insert is introduced in a through opening in a sandwich panel and welded to the opposed outer skins. Welding is realized by engagement of the insert by a welding apparatus at its frontal ends.
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CROSS-REFERENCES TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable.
REFERENCE TO A “SEQUENCE LISTING”
Not Applicable.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a safety icon and a combination integrating the safety icon and other technological elements into a Portable Area Safety Zoning system (PASZ) to create a variety of safe zones for military, police, and civilian uses.
(2) Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
Icons, i.e., entities whose form suggests its meaning, have been used for centuries. In today's computer age, most people associate icons with pictures, mainly the graphic symbols on a computer display screen that suggests the associated function, e.g., a pictorial depiction of a trash can for disposing of files. The concept of an icon, however, also includes objects, e.g., the Statue of Liberty, the Great Wall of China, and Mount Rushmore. For the purpose of this invention, a safety icon is an object which is instantly recognizable as a device which promotes safety. The focus of this invention comprises safety icons which set apart one area from another, usually a secured zone from an unrestricted zone for pedestrian, automobile, or aircraft traffic. The sample icon in the description of the invention comprises a variation of a traffic safety cone, but the scope of the invention disclosed and claimed is not limited to the specific physical form of the cone disclosed.
Traffic safety icons have come in many recognizable forms, including posts (U.S. Pat. No. 4,573,109), barrels (U.S. Pat. No. 5,722,788), pylons (U.S. Pat. No. 5,115,343), cones (U.S. Pat. No. 6,558,068), and signalling devices uniquely designed for a particular purpose (U.S. Pat. No. 6,174,070). (The patents listed in parentheses are representative of the types of safety icons mentioned; see the patents cited of record for a more comprehensive list.) By and large, each of them have limited usages and permit of only minor variations.
The manner of using the safety icons includes those which may stand alone (U.S. Pat. Nos. 5,597,262, 5,722,788, 6,556,147, and 5,529,429) or are permanently joined together (U.S. Pat. No. 4,515,499). Most safety icons, however, are temporarily attached to an adjacent icon by solid or flexible barriers (U.S. Pat. Nos. 5,501,429, 5,030,029, 6,053,657, and 6,386,135). The icons of interest in this category are portable and typically arranged to delineate an open or closed perimeter (U.S. Pat. Nos. 4,770,495, 5,501,429, 5,030,029, and 7,030,777). Those that are permanently connected to each other are difficult to store and transport, and those temporarily attached to an adjacent icon, again, lack sufficient versatility to justify being carried by military or civilian units having limited space and/or weight restrictions.
Of particular relevance to the disclosed invention are systems which utilize portable safety icons to control or monitor traffic (U.S. Pat. Nos. 4,515,499, 5,501,429, 6,559,774, and 7,030,777), to set up temporary landing sites for helicopters or airplanes (U.S. Pat. Nos. 4,862,164, 6,069,557, 6,174,070, 6,193,190, and 6,509,844), and to cordon off selected areas (U.S. Pat. No. 4,770,495). While all of these are suitable and effective for the functions for which they were designed, a study of their structures and operational requirements will make it immediately apparent that cross-over from one use to another is quite impractical if not impossible.
BRIEF SUMMARY OF THE INVENTION
The present invention overcomes the difficulties described above by integrating a plurality of safety icons with a variety of special-function modules to create a system of establishing a concomitant variety of safety zones having universal applicability under a variety of situations. A carrying case houses a set of safety icons. Each safety icon is collapsible so that it is compact for storage and travel and is extendable to provide a relatively large body which is sufficient to achieve its goals of being easily seen from land and air. The base of each safety icon includes a retractable, retro-reflective tape and anchor tabs for latching to retractable tapes of adjacent icons. The base of each safety icon is adapted to receive a plurality of modules. Each module is designed to be manually connected and removed from said base while being stably attached when connected. A variety of modules are provided, each of which are designed to perform a specific function. One type of module acts as a beacon guiding personnel to the icon, e.g., as with a light beam (LED, infrared, ultraviolet, halogen, etc.), a radio beam, or a GPS signalling beam. Other types of modules include sensors comprising video cameras, motion sensors, light sensors, explosive detection devices, etc., as will be described in more detail anon. The modules are small, compact, and are self-contained. A large variety of modules can be easily stored and transported, even under conditions where space is a premium. Assembly, deployment, and the dismantling of icons and modules is easily performed by relatively unskilled personnel. The PASZ system provides equal or increased safety as compared to prior systems, while adding needed versatility in functions allowing it to adapt to changing environments and needs. PASZ is an inexpensive system which provides military, police, fire and rescue, security, and other similar personnel, with affordable means to do their job safely and effectively.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, aspects, uses, and advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description of the present invention when viewed in conjunction with the accompanying drawings, in which:
FIG. 1 is a back view of a preferred embodiment of a collapsible safety cone;
FIG. 2 is a bottom view of the safety cone of FIG. 1 as seen along lines II-II in FIG. 1 ;
FIG. 3 is a front view of the safety cone of FIG. 1 ;
FIG. 4 is a top sectional view of the safety cone of FIG. 1 as seen along lines IV-IV in FIG. 3 ;
FIG. 5 is a top sectional view of the safety cone of FIG. 1 as seen along lines V-V in FIG. 3 ;
FIG. 6 is a schematic depiction of the locking mechanism of the collapsible safety cone of FIG. 1 ;
FIG. 7 shows a carrying case for four of the collapsible safety cones of FIG. 1 ;
FIG. 8 depicts a surveillance check-point utilizing the safety cones of FIGS. 1-6 ;
FIG. 9 shows a portable helipad created by proper placements of the safety cones of FIGS. 1-6 ;
FIG. 10 shows a portable landing strip created by the safety cones of FIGS. 1-6 ;
FIG. 11 shows the safety cones of FIGS. 1-6 cordoning off the area around a parked airplane; and
FIG. 12 shows the safety cones of FIGS. 1-6 cordoning off the area around a parked gasoline tanker truck at a commercial service station.
DETAILED DESCRIPTION OF THE INVENTION
A safety cone 10 is shown in FIG. 1 . Safety cone 10 comprises a basic element of the Portable Area Safety Zoning System (PASZ), a few representative applications of which are disclosed in FIGS. 8-12 , below. Safety cone 10 comprises a base 12 , and a plurality of collapsible cone segments 14 a - 14 d , the uppermost of which has a cone handle 16 integral therewith.
Base 12 is weighted to lower its center of gravity for stability, and the bottom 18 of base 12 ( FIG. 2 ) is preferably textured and/or covered with a non-slip material to assist in maintaining its position after placement. In the preferred embodiment, base 12 is square with four sides 20 ; other peripheral shapes, e.g., circular, triangular, octagonal, etc., are contemplated, however. Integral with and protruding from each of three sides 20 of base 12 is an anchor tab 22 which includes a vertically extending aperture 24 .
Referring to FIGS. 3-4 , a front view and a top sectional view taken along lines IV-IV of FIG. 3 , respectively, of safety cone 10 is shown. The fourth side 20 of base 12 has a slot 26 extending from the outer edge into the hollow interior 28 ( FIG. 4 ) of safety cone 10 . Mounted within hollow interior 28 is a retracting mechanism 30 for a retro-reflective, retractable tape 32 . (A retro-reflective surface is one which reflects incident light back in the direction from which it came, as opposed to scattering it or reflecting it in the direction away from the source, as in a mirror.) By locating retracting mechanism 30 centrally within base 12 , the center of gravity of cone 10 is further lowered and centralized, thereby increasing the stability of cone 10 . Slot 26 is stepped, having an enlarged portion leading into a narrower portion; see FIG. 4 . The flexibility of tape 32 plus the funnel-like shape of slot 26 allows tape 32 to exit slot 26 at various angles, generally within a 50° to 60° angle. Fixed to the free end of tape 32 is a hitch 34 , preferably comprising a pin 36 adapted to be latched securely within an aperture 24 of one of the anchor tabs 22 of an adjacent safety cone 10 , as will become apparent shortly. In the drawings, tape 32 is shown as extending a short distance outside of base 12 ; this is for illustration only. In practice, when pin 36 is not engaged with an aperture 24 , retracting mechanism 30 biases hitch 34 of tape 32 into the enlarged portion of slot 26 ( FIG. 4 ) for safety and compactness during storage and transportation thereof.
FIG. 5 is a top view of safety cone 10 as seen along lines V-V of FIG. 3 where the first two cone segments 14 a and 14 b are shown in section. Retracting mechanism 30 and tape 32 are as before. Base 12 includes a through opening 38 spaced inwardly from each corner. Corner openings 38 are suitably sized to receive anchoring stakes (not shown) when it is necessary to securely fix safety cone 10 to a surface.
Also included in base 12 are pairs of apertures 40 , each of which are located approximately midway of sides 20 and the lowermost cone segment 14 a . Aperture pairs 40 comprise mounts which are adapted to receive a corresponding pair of pins 42 depending from any one of a plurality of modules 44 , the types and applications of which are to be described relative to FIGS. 8-12 . Mounts 40 and pins 42 removably fix modules 44 to base 12 and can comprise apertures with slightly resilient walls into which pins are friction fit, threaded apertures and mating bolts, or smooth bores and selectively expandable shafts. A resilient friction fit is usually sufficient, as there are no external forces trying to separate modules 44 from base 12 , except when being manually removed. A resilient friction fit is preferred as well, as it allows for quick and easy attachment, withdrawal, and/or replacement of modules 44 . Up to four different kinds of modules can be accommodated by the four mounts 40 included in each cone, providing important versatility to the inventive concepts disclosed herein.
Collapsible cone segments 14 are locked in either of two states, an upper, extended state and a lower, storage state. Any known locking mechanism can be used, but the locking mechanism 46 , shown in FIG. 6 , is preferred. Locking mechanism 46 comprises a C-shaped slot 48 on the internal wall of the lower of the two cone segments 14 which cooperates with a fixed external locking pin 50 on the upper of the two cone segments 14 . When in the collapsed state with pins 50 at the blind end of the lower arms of C-shaped slots 48 , grasping handle 16 and rotating it counter-clockwise will move each locking pin 50 along the lower arm of its associated C-shaped slot 48 until all locking pins 50 are in register with the vertical bights of C-shaped slots 48 . To completely extend cone 10 , just pull upwardly until all locking pins 50 reaches the top of their vertical bights and rotate clockwise to move locking pins 50 outwardly to the extremities of the upper arms of C-shaped slots 48 . In this manner, all of cone segments 14 a - 14 d are simultaneously unlocked, extended, and locked by a simple twist, pull, twist motion which is easily effected by only one hand. Reverse the movements to collapse safety cone 10 . Mechanism 46 promotes quick and easy deployment of safety cones 10 , a desiderata infused throughout the design and use of the PASZ cones.
Safety cones 10 are designed to be used in the field to clearly and distinctly delineate safety zones. As such, they must be both of sufficient number to accomplish the goals and portable enough to be effectively deployed quickly and easily. A suitcase 52 ( FIG. 7 ) comprising a main body 54 , a lid 56 , a handle 58 and a pair of latches 60 houses a set 62 of four safety cones 10 . Sets of four safety cones, or multiples of four, have been found to be optimum for creating most perimeters of desired safety zones. Suitcase 52 provides storage for discrete sets of safely cones and facilitates transport thereof to the desired location of the safety zone. Temporary safety zones, also referred to herein as PASZ stations, are useful in a multitude of civilian and military situations. A few exemplary ones are shown in FIGS. 8-12 .
The military applications of PASZ are many. One of the most important is the surveillance of passing vehicles.
It is well known that our military personnel are subject daily to suicide bombers in vehicles rigged with explosives, a scenario likely to be repeated for decades to come. Early detection of them is crucial, but a hands-on inspection can be dangerous, since should the bomber suspect he has been discovered, he might intentionally detonate the explosives, putting anyone nearby at risk. Also, a surveillance zone must be established well removed from potential targets in order to further protect personnel, supplies, and equipment. The surveillance zone should be effective in identifying potential enemies while simultaneously providing safety for our troops. Such a safety zone comprising a PASZ station utilizing PASZ equipment and concepts can be achieved quickly and easily.
Exemplary is the showing in FIG. 8 , wherein two lanes of a highway 64 , both for Northbound traffic (bottom to top in the drawing), are shown. A surveillance zone is established by two sets 66 and 68 of safety cones 10 interconnected by retro-reflective, retractable tapes 32 . Set 66 defines a merge-directing fence, and set 68 , placed alongside the roadway, establishes a boundary restricting passage of vehicle 70 to a narrow slot shown as comprising a single lane of highway 64 . Vehicle 70 is slowed and directed by sets 66 and 68 into the open lane to facilitate inspection thereof.
A plurality of modules 44 ( FIG. 5 ) are mounted on the base 12 of each cone 10 . Each module is designed for a specific purpose and is self-contained. That is, each comprises a detector suitable for the function needed at the specific PASZ station and a transceiver for receiving control signals, where appropriate, and for sending images, data, and/or other information to surveillance personnel 72 .
In a vehicle surveillance system, as in FIG. 8 , each cone 10 has a module 44 comprising a video camera module facing the roadway. Being mounted on the base 12 of cones 10 , virtually at ground level, the cameras are capable of inspecting the bottom of vehicle 70 for any signs of unusual modifications, such as anything which is indicative of the presence of explosives. Also mounted on each base 12 are modules 44 comprising explosive “sniffers,” devices capable of detecting minute amounts of gaseous emanations from various types of explosives. Other types of chemical or other particle detector modules suitable for sensing materials commonly used in chemical warfare weapons could be attached to cones 10 where indicated. Radiation sensing modules 44 can also be mounted on cones 10 , should it be suspected the vehicle is transporting radioactive materials. And, motion sensor modules to detect the presence of a moving body and accelerometers for detecting collisions with the cones also find applicability in PASZ surveillance stations. This list of types of modules 44 is not exhaustive. Others can easily be designed for detecting or observing other specific parameters of interest and find utility as removable modules on safety cones 10 in a PASZ system.
A portable, remote controlled video camera 74 is preferably included near the PASZ station to permit a close look at the type, color, and make of vehicle 70 , its license plate, and the driver and passengers. Video camera 74 can be positioned at an optimum location for an early look at the occupants of vehicle 70 . Camouflaging video camera 74 or otherwise hiding it from view permits observing said occupants without arousing their suspicions. Additional video cameras 74 can be strategically placed in order to coordinate with each other in inspecting larger vehicles (tanks, trucks, vans, SUVs, etc.) in more detail. One such optional video camera 74 a is shown behind set 66 of safety cones 10 . An interrogation system comprising speakers and microphones are preferably included with video camera 74 a . An automatic voice language translation device is also preferably included with video camera 74 a , in order to automatically translate the driver's language into English. All video camera systems are equipped with remote control capability to allow for their operations from a safe distance.
All images, data, and other information are immediately transmitted in real time to a central control station 76 , preferably a portable computer 78 in operable contact with a control vehicle 80 . Preferably, communication between modules 44 and control station 76 is by wireless transmission. When jamming or interception of signals is possible, hard-wiring the components is within the PASZ system's operating parameters. For instance, all modules which transmit or receive signals have input and output ports for receiving cables connecting them to other modules and/or to central control 76 , permitting hard-wiring of all appropriate components. Control vehicle 80 is suitably equipped with a sophisticated computer having software which synthesizes and analyzes the data using linked programs, including face recognition databases, language translation databases, vehicle information databases, etc., and forwards its results to computer 78 for human interpretation. Upon reviewing the incoming data, surveillance personnel 72 direct the actions of local forces whose response is immediate.
Control point 76 is shown adjacent safety cone set 66 for convenience in drawing only; in a real environment, control vehicle 80 and its operating personnel would be as far removed from the area as is practicable. Thus, the entire surveillance is effected without endangering anyone at all.
Multiple modules of the same type increase the capabilities of the PASZ surveillance system. For example, all images from video modules 44 can be merged by software in control vehicle 80 for viewing in computer 78 to provide an extended, seamless picture of the underside of the car, as if an observer were beneath the car travelling along with it, inspecting its underside. In like manner, the detected gasses from sniffer modules 44 can be added together to give a cumulative reading which is more sensitive than one module acting alone would be. If the single lane were extended for a great distance, e.g., a mile or so, a comparison of the signals from motion detector modules 44 would pinpoint the location and speed of the vehicle passing through. Accelerometer modules 44 would immediately detect any collision with a safety cone 10 indicating an excursion from the delineated single lane, should the driver of vehicle 70 panic, try to escape, or change targets to include the surveillance personnel 72 . Deviations from the restricted lane of travel would sound an alarm, thereby giving advanced warning of suspicious activities of a subject vehicle.
Computer 78 provides an immediate evaluation of the incoming data by personnel 72 on the scene. It is an important part of the PASZ surveillance system, however, that all data be relayed via satellite to a home base (not shown) to be evaluated in more detail by highly trained computer specialists equipped with larger, faster, and more sophisticated computers. For example, the facial images transmitted by video camera 74 could be analyzed by facial recognition software in a larger database in a larger computer at the home base. The home base could be located miles away, for example, at the general headquarters of the command. It would comprise an intelligence center capable of receiving, processing, and integrating data from a plurality of PASZ stations. The coordination of the efforts of the entire command is clearly enhanced by the capabilities of the portable PASZ systems.
When viewed from a distance, a set of safety cones, such as sets 66 and 68 , are seen along the line of cones, so they appear as a substantially solid wall. When viewed in passing, however, if all that connects adjacent cones are imaginary lines which exist only in the minds of the viewers, the safety boundary can easily be visually lost. Retro-reflective, retractable tape 32 obviates the problem by providing an easily seen, physical connection between cones 10 . Since the driver of vehicle 70 is assumed to be able to clearly see tapes 32 , any deviations from the path designated would be interpreted as a deliberate attempt to flee the area instead of an unintentional error of a nervous but innocent driver. Tapes 32 provide a positive, clearly seen perimeter, the crossing of which triggers an advanced warning, therefore, of intended harm.
As in any military operation, fast and easy deployment is important.
Establishment of the PASZ station shown in FIG. 8 meets those requirements. Two suitcases 52 , easily transported to the site, is sufficient to provide enough safety cones 10 to merge two lanes of traffic into a single lane along a highway, although more suitcases and cones can of course be employed. Safety cones 10 are easy to set up quickly by a limited number of relatively unskilled personnel. The specific types of modules needed for the anticipated situation are easily identified, selected, and attached to cones 10 either beforehand, on the way to the site, or after placement of the cones has been completed. Breaking the PASZ station down for transport to another location is likewise quick and easy.
The PASZ station shown in FIG. 8 can obviously be applied to civilian uses. The variability and interchangeability of the different types of modules, the collection and analyzation of the data, and the transmission of the data and results to a central home base give valuable assistance to civilian authorities, for example, to troopers manning a police roadblock or DUI checkpoint.
Another important military application of the PASZ system is shown in FIG. 9 .
Temporary helipads 82 are often needed when troops and/or supplies are deployed behind enemy lines. It is unreasonable to ask a helicopter pilot to select a suitable landing site when flying in unfamiliar territory, especially at night or during inclement weather. Selecting and delineating a site suitable as a temporary helipad is best left to a reconnaissance team on the ground.
Speed of deployment and safety for all concerned are prime considerations in creating and using a temporary helipad. From the reconnaissance team's point of view, speed and stealth minimizes the dangers of being discovered. The PASZ system, as has been seen, is capable of being quickly and easily set up and quickly and easily broken down. Two suitcases containing two sets of cones is all that is needed and are relatively easily transported to the scene.
Most prior art systems for setting up temporary helipads comprise a plurality of portable beacons, e.g., cones, lighted posts, etc., which are individually positioned by hand with no visible means interconnecting adjacent beacons. Such systems inherently present problems for ground and air personnel. The landing site is of necessity quite large, and the beacons are spaced apart often on uncompromising terrain by a person or persons who, being unable to see the arrangement of the beacons from above, cannot see if their placement clearly and unambiguously defines the landing area. The dangers are amplified when the construction is being done at night. The PASZ system connects the beacon cones with retro-reflective tapes. The overall configuration formed by the tapes are more easily seen by the reconnaissance team than an imaginary perimeter produced by the cones alone. This speeds up the layout of the temporary helipad, lowering the potential for danger to the reconnaissance team.
But the temporary helipad must also promote safety for the incoming pilots and accompanying personnel. An arrangement which looks good from the ground may not look as good from the air, especially when individual light beacons are positioned to simulate the oft-used Y-type landing strip. To one standing in the middle of the arrangement, its arrangement may appear close to perfect. From the air, at night, approaching the temporary helipad from changing directions and changing descent angles, the perceived pattern of the collection of lights changes continually, possibly confusing the pilot as to the location and orientation of the helipad. At times, the terrain will not permit perfect arrangements, even from ground personnel perspective; the resulting misarranged guides can be even more confusing to the incoming pilot, obviously creating extremely dangerous situations.
The PASZ combination of cones with retro-reflective tapes clarifies the helipad location, size, perimetrical configuration, and orientation for the helicopter pilot. The beacon modules on the cones guide the pilot to the general area, but unlike the pattern produced by unconnected individual cones which could be incomprehensible to the pilot, tapes 32 clearly and unambiguously mark the perimeter of the temporary helipad, day or night. Tapes 32 are brightly colored so as to be easily seen during the day. When making a night landing, incoming helicopters would, after being guided to the area by the beacons, typically scan the terrain with highly focused search beams, either with visual light or with infrared beams whose reflections are sensed electronically by infrared detectors or visually by night vision goggles. As mentioned earlier, tapes 32 are preferably of the retro-reflective type. Tapes 32 , therefore, limit the reflections of the incoming highly focused search beams to highly focused beams reflected directly back to the pilot. The resulting visual image produced by connected tapes 32 clearly defines the landing zone of the helipad, removing all doubts as to the precise location of the landing point. The retro-reflective tapes 32 are passive in their emissions, so unwanted detection of the site is minimized, while the pilots ability to visualize the landing site's perimeter is enhanced.
Since the beacons used in locating the helipad site are not required to be the sole elements defining the outline of the landing site, they may be of the type which have relatively small outgoing signals. Their size, weight, and power requirements are consequently minimized, making them cheaper to manufacture, easier to store, and easier to transport. More importantly, the potential for detection by the enemy is reduced, thereby improving the safety margin for our troops.
Referring to FIG. 9 , a temporary helipad can be created by the PASZ system with a minimum of sets of safety cones, just two suitcases. One set 84 of safety cones 10 are arrayed in a roughly C-shaped configuration opening in one direction. Another set 86 of safety cones 10 are arrayed in a similarly roughly C-shaped configuration which is opening in the opposite direction, facing set 84 . The combination of arrangements of sets 84 and 86 of cones 10 are sufficient to define a generally circular perimeter for helipad 82 . When possible, and subject to clear, unambiguous understandings between ground crew and pilots, the gaps between cones 10 at the top and bottom (as seen in FIG. 9 ) of helipad 82 , where no tape 32 is present, could be informative, as well, indicating a suggested direction of descent and ascent or providing an indication of wind directions. Of course, this arrangement is merely illustrative, as more cones 10 could be employed, and the circular perimeter could be closed by connecting all tapes 32 to an adjacent cone 10 .
The types of modules 44 selected for helipad 82 are chosen based on the function of guiding the helicopter pilot to helipad 82 and are affixed to bases 12 of cones 10 . Beacons may be of any known type and design. Beacons that generate light, e.g., visible light from Xenon or halogen bulbs, invisible light from infrared or ultraviolet sources, such as LEDs, or coherent light from laser beams, are suitable. Beacons including homing signals comprising radio signals or GPS signals are preferred for guiding the pilot to the general site location. Any of the aforesaid beacons may be activated manually by the reconnaissance team or remotely by transceivers in modules 44 responding to signals from the incoming helicopters.
A landing helicopter 88 creates a tremendous down-draft which could blow one or more cones 10 out of position. PASZ cones 10 include several features which resist the down wash from helicopters. Base 12 is weighted, and retracting mechanism 30 is centrally located internally of base 12 ; both act as ballast which is usually enough for the stability of cone 10 . The aerodynamically friendly shape of cones 10 resists ill effects from high winds, also. In the extended state ( FIGS. 1 and 3 ) cones 10 have a tapered conical shape with circular cross-sections which inherently promotes smooth airflow therearound. Also, cones 10 are collapsible which reduces the height and consequently the total “sail” area exposed to the down-draft. If all else fails, anchoring stakes can be inserted through corner openings 38 and driven into the ground.
The helicopter down-draft could also lift tapes 32 sufficient to separate hitches 34 from the anchors 22 of their associated cones 10 . Hitch pin 36 of hitch 34 at the free end of tape 32 preferably extends vertically upwardly, as shown in FIGS. 3 and 4 , and can be linear or curved to form a hook. When placing hitch pin 36 upwardly through aperture 24 , hitch 34 is beneath anchor tab 22 . The weight of cone 10 bears down upon hitch 34 , holding tape 32 flat against the ground. Tape 32 is preferably made of a material having a high tensile strength to resist forces tending to displace or rupture it.
Should the ground team be required to leave a temporary helipad 82 behind, because there is not enough time to remove the anchoring stakes, nothing which could be of real value to an enemy need be left. Modules 44 , which are the only parts of a PASZ station which might include classified technology, are easily and quickly removable.
PASZ stations which create temporary helipads, as in FIG. 9 , clearly have civilian applications as well. Fire and Rescue crews which respond to accidents, fires, or natural disasters would find it useful to carry one or more suitcases 52 . For example, lane closures of the type shown in FIG. 8 cordoning off accident scenes can be quickly and easily effected using PASZ technology. For serious accidents requiring helicopter rescues, a PASZ station helipad, such as shown in FIG. 9 , will guide pilots to safe landing sites and away from dangerous obstacles which may not be easy for them to see from the air, such as power lines. Rescues from mountainous areas, where flat surfaces might be difficult to identify from the air, can be facilitated by the PASZ system. PASZ's portability permits ground crews to carry them through rough terrain to find the optimum location for setting up a PASZ helipad.
Temporary runways 90 for larger aircraft, as shown in FIG. 10 , are quickly and easily outlined by the PASZ system. A set 92 of safety cones 10 are linearly aligned and joined together by attaching retro-reflective tape 32 to the adjacent cone. A similar set 94 is located parallel to set 92 and spaced apart sufficiently to accommodate the largest airplane 96 anticipated to land there. Beacon modules 44 would guide the pilots to the runway, and the brightly colored, retro-reflective tapes 32 would show quite clearly the edges thereof.
Establishing temporary runways for military aircraft in hostile surroundings, such as in open deserts, is clearly important, but other applications in other venues are within PASZ's capabilities. Delineating a segment of an open highway, for example, which has been cleared for an emergency landing is accomplished quickly and easily with the PASZ system. PASZ permits the quick and easy establishment and identification of a specific commercial runway for emergency use. When the runway designated for an incoming airplane must suddenly be closed because of an accident, pilots of approaching aircraft can be clearly and unambiguously directed to an alternate runway by swift deployment of a PASZ runway 90 . The speed permitted by PASZ systems in establishing such an alternate runway can, of course, be crucial in achieving a safe landing.
There are innumerable circumstances in which an area must be cordoned off for security or safety reasons. Easily recognizable examples include police crime scenes, highway work zones, Hollywood celebrity functions, rock concert entry ways, and many, many more. The common factor in each is that restricting the area is localized both in time and in place; they are to be cordoned off in a specific place for a specified period of time, and then to be restored to their original unrestricted status. The PASZ system is ideal for establishing temporary perimeters. Two such examples are shown in FIGS. 11 and 12 .
In FIG. 11 , a safety zone is established around the wings of an aircraft 98 by two sets 100 and 102 of cones. Retro-reflective, retractable tapes 32 are capable of being extended outside of cones 10 to various lengths, from zero feet (unextended) to a minimum of fifteen feet each, thereby allowing the PASZ system to adapt to any size or shape work area. By lying flat on the ground, tapes 32 also allow work vehicles to enter and leave the PASZ stations. For example, if the luggage on board the aircraft 98 is being off-loaded, baggage carts can be brought within feet of the cargo bays without disturbing the cones 10 or tapes 32 . If mechanical work is being performed on the aircraft, repair vehicles can approach as close as is needed while still being off-limits to nonessential personnel. When the job is finished, the PASZ stations are returned to their suitcases 52 (not shown in FIG. 11 ) for transporting to the next job site or for storage.
When neighborhood service stations 104 receive a shipment of gasoline, as shown in FIG. 12 , the facility does not close to the public during the delivery. Dispensing gasoline at the pumps 106 and shopping at the station's mini-mart 108 continues unabated. This activity can expose the scene to potential danger, e.g., from a carelessly thrown cigarette butt near the fumes emanating from gasoline tanker truck 110 or from a driver not giving sufficient attention to controlling his vehicle 112 . The bright colors and reflective qualities of the PASZ station 114 clearly alerts the public to stay away from the delivery area 116 . Modules 44 are selected appropriately to further warn passersby to stay clear of delivery area 116 . Motion sensors which activate flashing lights, beeping horns, moving mechanical structures, such as a waving flag, an oscillating or rotating arm, etc., and a PA system on truck 110 to play recorded messages, are among the modules 44 available to warn patrons and workers of unwanted intrusions into the delivery area.
From the preceding, it is clear that the PASZ system has numerous useful applications, from protecting our troops in war to protecting ordinary citizens in everyday activities. The diversity of uses is due to the integration of a wide variety of modules and the PASZ safety cone into a novel system for establishing PASZ stations. The entire system is easily portable due to cones 10 being collapsible such that they can be stored in suitcases 52 and transported with minimum difficulty to and from the selected PASZ site. Permanently enclosing the retracting mechanism 30 within its cone 10 simplifies the combination and facilitates its handling. The ability to selectively attach one or more modules 44 having specific functions enlarges the number and types of environments within which the PASZ system is uniquely effective. And, transforming from one type of PASZ system to one of the many other varieties of PASZ systems is effected quickly and easily by ordinary people without the need for extensive training in highly technical subjects.
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, methods 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 as defined in the appended claims.
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 solely by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is to be understood that the disclosure is by way of illustration only and that the scope of the invention is to be limited solely by the following claims:
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Temporary safety zones are established by deploying a plurality of safety icons connected by extensible, brightly colored, retro-reflective tapes. The tapes are retracted within the housings of the safety icons. A plurality of modules having different functions are removably affixed to the base of the safety icons, the modules including sensors, beacons, transceivers, detection devices, and audio receivers and video cameras. Because the modules are manually interchangeable, the safety zones can be implemented for specific, interchangeable circumstances, e.g., a surveillance station, portable helipad, landing strip, and restricted area barriers.
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BACKGROUND OF THE INVENTION
The present invention relates to digital data processing apparatus and more particularly to apparatus for adjusting the phase of data signals arriving at utilization circuitry so as to compensate for uncontrollable phase shifts originating apart from the data utilization circuitry.
As digital data processing systems have become faster and more complex, an increasingly serious problem has been that of synchronizing the various data and clock signals which are utilized throughout the system. As the data and clock rates are pushed ever higher, the delays associated with even short lengths of wire become significant due to the phase shift they introduce, owing to the finite speed of propagation of pulse signals along the wire. To date, most efforts at dealing with these problems have concentrated on keeping circuit paths as short as possible. Even so, in certain high speed systems it has been necessary to tediously adjust wire or cable lengths on an empirical basis so as to assure that the data and clock signals arrive at a given utilization circuit with the proper phase relationship so that data errors will not occur.
Problems of timing are compounded in multiprocessor systems since it becomes extremely difficult to equalize the transit times between all combinations of subsystems, even though various of these subsystems may each be considered a region of substantially synchronous operation. While it is possible to globally distribute a clock signal of precisely controlled frequency, it is difficult to control relative phasing from one region to another. Another source of timing problems originates with the variation of delay with changing temperature through the various input and output buffer circuits which are normally associated with each data line of significant length.
While the need for phase adjustment in accordance with the present invention is necessitated by the use of very high speed data transfer rates and the relatively significant magnitude of the phase shifts introduced by variations in signal path lengths, it will also be understood that changes in such delays typically occur relatively slowly. Such delays are, for example, introduced by the heating up of the transistor junctions which comprise the digital logic gates generating and receiving the data signals. Accordingly, while the initial adjustment needed may not be known and the cause of changes in phase shift may be both unknown and unpredictable, it is not necessary to make adjustments at a relatively high rate since the changes will be relatively gradual once the system is up and operational.
Among the several objects of the present invention may be noted the provision of apparatus for automatically adjusting the phase of data signals arriving at utilization circuitry so as to compensate for uncontrollable phase shifts originating apart from the utilization circuitry; the provision of such apparatus which will operate automatically; the provision of such apparatus which facilitates very high speed operations; the provision of such apparatus which facilitates the cooperative operation of multiple regions of synchronous behavior in a digital data processing system; the provision of such apparatus which is highly reliable and which is of relatively simple and inexpensive construction. Other objects and features are in part apparent and in part be pointed out hereinafter.
SUMMARY OF THE INVENTION
Briefly, apparatus in accordance with the present invention employs an adjustable delay line which provides to a data signal a delay of selectable duration. The delayed data signal is compared with a local standard for a plurality of different delay durations and discrepancies in the comparisons are detected. The selection of a particular delay to be applied to the data signal provided to the utilization circuitry is then based upon the detected discrepancies.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of automatic phase adjusting apparatus as constructed in accordance with the present invention;
FIGS. 2-7 are more detailed logic diagrams of circuitry implementing component parts of the system of FIG. 1; and
FIG. 8 is a timing diagram representing clock signals uitlized by the apparatus of FIGS. 1-5.
FIG. 9 is a chart defining the logic symbols used in the diagrams of FIGS. 1-5.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As indicated previously, it is an object of the present invention to automatically adjust the phase of data signals arriving at data utilization circuitry so as to compensate for phase shifts originating apart from the data utilization circuitry. With reference to FIG. 1, incoming data from an external source arrives on a lead designated generally by reference character 11 while the phase adjusted data is provided to utilization circuitry 13 over a lead designated generally by reference character 15.
To provide a delay which is adjustable over a range of values (durations), the apparatus illustrated employs a plurality of delay lines, five in the particular embodiment shown. These delay lines are designated by reference characters 21-25. A selector circuit 27 which is under the control of the automatic adjusting system described hereinafter is provided for coupling to the data output lead 13 a data signal which has been subjected to a delay of selected duration.
In the embodiment illustrated, the delay lines 21-25 are clocked digital delay lines, the timing for the progressive delays being controlled by four high speed clock signals CL1-CL4. Preferably, the high speed clock signals CL1-CL4 have a frequency which essentially corresponds to the nominal pulse width employed in the incoming data signals so that it can be reasonably expected that data transitions will periodically occur within the range of delays provided by the several delay lines. The relative phasing of the clock signals is represented in FIG. 6. With reference to the delay lines of FIG. 1 and also their detailed representation in FIG. 3, it may be noted that one of the clock signals CL1 is utilized twice in generating the progressive delays.
In addition to the symmetrical clock signals CL1-CL4, the apparatus of the present invention also utilizes a pair of slower clock signals CL5 and CL6. The slower clock signals comprise pulses which have an individual pulse timing which corresponds to individual pulses of the clock signals CL1 and CL3, respectively, but these pulses occur at a rate which is a sub-multiple of the high frequency clock rate.
As is described in greater detail hereinafter, the operation of the control circuitry described herein determines whether a data transition occurs in the interval between the delays provided by an adjacent pair of the successive delay lines, there being four such intervals. There are correspondingly four possible choices of delays. The longest delay is, in essence, used only to provide an endpoint for the defined interval which corresponds to the longest of the delay lines which will be considered for possible selection.
At successive points in time determined by the period of the clock signals CL5 and CL6, the state of the output signal from each of the delay lines 21-25 is captured or sampled by a respective latch 31-35. For each adjacent pair of successive delay lines, an EXCLUSIVE OR (XOR) gate is provided for combining the signals held in the respective latches, the gate output signals being designated ST1b-ST4b. As will be understood by those skilled in the art, a respective one of these gate output signals will be asserted if a data transition occurred in the interval between the successive delays provided by the two delay lines which feed that particular gate, in other words a discrepancy in the latched outputs of the respective delay lines caused by the occurence of a data signal transition in the interval defined by the two different delay values. Further, assuming that the clock rate for the data signal corresponds to the clock rate for the clock signals CL1-CL4, no more than one of the gate output signals will be asserted during each cycle of operation.
As will be understood by those versed in the art, the "asserted" state of a digital signal may be either the zero (low) or the one (high) state depending upon the logic scheme employed. In other words, the term "asserted" basically means that the necessary condition has been met. In the signal naming convention employed in FIGS. 1-5, signals whose designations end with a "b" are low when asserted and the others are high when asserted.
While transitions in the incoming data signal and the clocking of the delay lines occurs at a very fast rate, the sampling accomplished by the latches and the operation of the rest of the control circuitry is driven at a slower clock rate to assure that the various sampling latches will reach stable states before decisions are made. As will also be understood by those skilled in the art, the fact that the delay lines provide progressive delays means a very increased likelihood that one of the phase shifted data signals will arrive at one of the latches just at the instant at which it is being clocked. Accordingly, it will also be understood that there exists a chance that the latch may be thrown into a metastable state from which a substantially increased time is required to settle.
The output signals from the XOR gates 36-39 are provided to a component sub-system conveniently designated as a FOUR-FLOP. This circuit, designated generally by reference character 41, comprises four NAND gates which are interconnected to generate four signals no more than one of which can be asserted at any given time. As indicated previously, only one of the output signals from the XOR gates 36-39 should be asserted at any one time under normal circumstances, but the FOUR-FLOP 41 assures that no more than one signal is asserted.
As is explained in greater detail hereinafter, the one asserted output signal from the four-flop circuit 41 represents a possible choice for selecting one of the delayed data signals. In order to provide an operation which is stable and which provides a good, long-term (in a relative sense) choice for a compensating delay, the apparatus of FIG. 1 provides circuitry, designated generally at reference character 43, for comparing each new possible choice with a previous or "candidate" choice. The system further comprises counter circuitry, designated generally by reference character 45, for controlling the loading of new candidate choices and for changing the actual selection only after consistent behavior makes such changes logical. This latter process can be considered as one of integration or averaging.
Referring now to FIG. 5 which illustrates the comparison circuitry in greater detail, it may be seen that this subsystem comprises, along the left side of the drawing, four similar gate arrays, each of which comprises, at its lower portion, a ring memory or latch which is capable of holding a value applied to the respective input lead during successive operating cycles and, in the upper series of gates, means for applying new values to the memory element. Transfer or loading of a new possible choice originating in the FOUR-FLOP circuitry to the latches in the comparison circuitry is controlled by a signal designated LD (LOAD) and its complement LDb which are generated by the counter circuitry 45 as described hereinafter. For each of these four input and latch components there is also a corresponding XOR gate system which compares the new value with the old value. The respective XOR gates are designated by reference characters 51-54. In one sense, the output signals from the XOR gates 51-54 may collectively be considered as a servo loop error signal which is used in automatically adjusting the selected value of delay as described hereinafter.
The signals generated in these first two sections of the comparison circuitry are logically combined in an array of gates designated generally by reference character 55 to generate signals, designated UP, DOWN and HOLD, which are provided to the counter circuitry 45 which provides averaging or integration as described previously. In general, it may be noted that the UP signal is generated when the new possible choice agrees with the held value; the DOWN signal is generated when the new possible choice disagrees with the held value; and the HOLD signal is generated if, within the current cycle of operation, no data transition has been detected.
The counter or integration circuitry 45 is implemented in the form of a shift register shown in greater detail in FIG. 6. This circuitry is arranged so that, in effect, a single bit is shifted up and down a linear array of four similar stages. In general, the asserted bit is shifted upwards, i.e. to the right, when the UP signal is asserted and is shifted to the left, i.e. down, when the DOWN signal is asserted. It should be noted, however, that the gates generating the UP and DOWN signals (FIG. 6) take into consideration the signal designated HOLD so that a bit is shifted neither up nor down during any cycle when the HOLD signal is asserted. As may be seen from FIG. 6, the HOLD signal is generated as a NOR function of the four signals originating in the four-flop circuitry and representing the new possible choice. However, as is understood by those skilled in the art, a data stream comprising a succession of zeros or a succession of ones will not provide transitions which can be examined by the circuitry of the present invention to aid in judging what may be the proper compensating delay. Accordingly, in accordance with the practice of the present invention, operational cycles in which there is no data transition are not counted in the integration process which effects the logical decision.
From the foregoing description, it can be seen that, in general, movement of the bit to the right shift register indicates consistency or stability in successive possible choices being presented to the comparison circuitry while shifting to the left is the response to a difference between the possible choice and the candidate (stored) choice. If the bit is shifted all the way to the right, the candidate is accepted as the actual selection and is applied, through the select latch 57, to the selector 27. Conversely, if the bit is shifted all the way to the left, the newest possible choice (represented by the output of the FOUR-FLOP circuit 41) is transferred into the latches in the comparison circuitry and becomes the new candidate choice for selection.
As described previously, the operation of the control circuitry described herein determines whether a data transition or discrepancy occurs in the interval defined by the delays provided by an adjacent pair of the successive delay lines, there being four such intervals. There are correspondingly four possible choices of delays. Since the period of the clock signals CL1-CL4 corresponds to the expected data pulse width or period, it can be seen that the four choices in one sense constitute a circular array which in effect folds back on itself. Proceeding with this analogy it can further be seen that the most desirable choice is the delay line which is opposite, within this circular array, from the delay intervals which encompasses the most transitions or discrepancies. In other words, the desirable choice is the one which provides a timing away from transitions, i.e. when the data signal is clearly in one or the other of its two stable binary states. In the signal nomenclature employed in defining the circuitry, this rotation or choice of the opposite is evidenced in the FOUR-FLOP circuitry of FIG. 4 where it can be seen, for example, that the interval T3-T2 is operative in producing a corresponding output signal (choice) ST2b while the interval Tl-T2 produces a signal ST4b.
Given the present high density capability of very large scale integrated circuits, it is possible to implement the circuitry described herein in a very small portion of the available chip area and it is thus feasible to provide an automatic phase adjusting system in accordance with the present invention at each of the lead lines which bring in data from the outside world and still have sufficient remaining chip surface area for major functions, i.e. the functions incorporated and provided in the utilization circuitry.
As noted earlier, the sampling, analysis, and adjustment processes performed by the present invention do not need to be performed at a high rate. Rather, only the delay line clocking and initial latching has to be performed by high speed circuit components. Once the appropriate selection is initially established, the need to change the selection should occur relatively infrequently and only gradually. Thus, while the presently preferred embodiment employs dedicated or so-called hard wired logic to implement the desired functions, it should be understood that the comparison, analysis, and adjustment functions might also be implemented by means of programmed logic, i.e. a microprocessor or a computer. In such a case, portions of the utilization circuitry might participate in the phase adjustment function on a time-shared basis with the other or principal functions of the utilization circuitry.
Further, while the embodiment described operates by sampling whatever data transitions may exist on the input line, it should be understood that there may be some applications in which it is desirable to periodically place a predefined data pattern on the input line and to compare successively delayed versions of the input signal with a reference or standard which also has a predetermined pattern rather than a monotonic clock as in the example described.
In view of the foregoing, it may be seen that several objects of the present invention are achieved and other advantageous results have been attained.
As various changes could be made in the above constructions without departing from the scope of the invention, it should be understood 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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In the apparatus disclosed herein, a data signal to be phase adjusted is applied to a plurality of delay lines providing progressively greater delays. The outputs of the several delay lines are compared over a period of time and a selection of one of the output signals for utilization is made based on choosing that delay line output which is in opposition to that pair of outputs which straddles or encompasses the most transitions.
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RELATED APPLICATIONS
[0001] This application claims priority from and incorporates by reference United States Provisional Patent Application 60/214,976, filed Jun. 29, 2000, by the present inventor, Robin Bhagat, and four others, and which is titled INTERRUPT CONTROLLER.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to interruptible computer systems, and more specifically to an interrupt controller for ARM and THUMB interrupt service routine switching, and that provide an interrupt-disable control bit.
[0004] 2. Description of the Prior Art
[0005] Interrupt mechanisms in microprocessors allow input/output (I/O) and other peripheral controllers to request immediate service. This is more efficient than routinely checking with all such requesters to see if they need service. Interrupt controllers allow several interrupt sources to be prioritized and/or masked. One type of prior art interrupt controller jammed processor instructions on the databus that the processor was expected to execute. Other conventional priority interrupt controllers can cause a processor to branch unconditionally to a reserved section of main memory, e.g., a vector table. Each interrupt level will unconditionally branch the processor to a corresponding part of the vector table. From there, an interrupt service routine (ISR) can be executed that is customized for the particular interrupt priority level.
[0006] The ARM7TDMI is a highly popular and broadly licensed synthesizable 32-bit RISC microcontroller core. The “T” in TDMI refers to the so-called “Thumb” 16-bit RISC instruction set execution, the “D” refers to boundary-scan cell arrays for hardware debugging, the “M” refers to a built-in 32-bit arithmetic multiplier, and the “I” refers to an embedded in-circuit emulation (ICE) breaker cell provided for software debugging.
[0007] One of the key features of the ARM7TDMI microcontroller is its ability to run two instruction sets, e.g., ARM 32-bit instructions, and Thumb 16-bit instructions. The Thumb instructions are essentially decompressed in real-time during execution into ARM instructions. Executing a “BX” instruction will cause a switch between the two instruction sets. Due to the idiosyncrasies of these instruction sets, a lot of program code space can be saved by running the processor in the Thumb mode. The ARM mode offers higher performance, but at a cost in code space usage.
[0008] When an interrupt request is first received, the ARM7TDMI processor will switch, by design, to ARM instruction execution. So if program code space needs to be saved, every ISR will begin with the ARM instructions needed to put the processor in Thumb mode, e.g., a sort of ISR preamble. Similarly, the ends of the ISR's are generally duplicates of one another. For example to return the processor to ARM instruction execution. When program code space is really tight, such duplications are too costly.
SUMMARY OF THE PRESENT INVENTION
[0009] Briefly, an interrupt controller embodiment of the present invention includes specialized interfaces and controls for ARM7TDMI-type microcontroller cores. Such sends interrupt vectors and IRQ or FIQ interrupt requests to the processor depending on particular interrupts received.
[0010] An advantage of the present invention is that an interrupt controller is provided that allows each interrupt input to be enabled and disabled.
[0011] Another advantage of the present invention is that an interrupt controller is provided that allows a global interrupt enable and disable which can be used to protect the critical code execution in the software or operating system.
[0012] A further advantage of the present invention is that an interrupt controller is provided that provides for priority-based FIQ and IRQ vectoring.
[0013] A still further advantage of the present invention is that an interrupt controller is provided that has programmable fixed-order interrupt priorities.
[0014] Another advantage of the present invention is that an interrupt controller is provided that has selectable ISR preamble code vectoring.
[0015] These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiment which is illustrated in the drawings.
IN THE DRAWINGS
[0016] [0016]FIG. 1 is a functional block diagram of a microcomputer system embodiment of the present invention;
[0017] [0017]FIG. 2 is a functional block diagram of an interrupt controller embodiment of the present invention;
[0018] [0018]FIG. 3 is a functional block diagram of the resisters and interrelationships in an interrupt controller for interrupt vectoring with an ISR preamble enabled; and
[0019] [0019]FIG. 4 is a functional block diagram of the resisters and interrelationships in an interrupt controller for interrupt vectoring with the ISR preamble disabled.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] [0020]FIG. 1 illustrates a microcomputer system embodiment of the present invention, and is referred to by the general reference numeral 100 . The system 100 comprises an ARM7TDMI synthesizable 32-bit RISC microcontroller core 102 connected to a program code memory 104 . A typical ARM7TDMI core die size is less than five square millimeters with 0.6 μm technology. All the components of FIG. 1 are intended to be incorporated on a single integrated circuit die.
[0021] An interrupt controller 106 collects and prioritizes a variety of system interrupt sources, e.g., a PCMCIA card 108 , an ATA disk controller 110 , a buffer-access controller 112 , a serial I/O controller 114 , a disk servo controller 116 , a timer 118 , a system control 120 , a memory access controller (MAC) 122 , a motor 124 , and a universal asynchronous receiver-transmitter (UART) 126 .
[0022] The interrupt controller 106 is able to issue two types of hardware interrupts, a fast interrupt request (FIQ) 128 and a normal interrupt request (IRQ) 130 . The processor 102 receives either an ARM 32-bit instruction stream 134 or a Thumb 16-bit instruction stream 136 , depending on operating mode. A “BX” instruction execution is needed to switch between operating modes.
[0023] The exception processing causes an abrupt change in program flow, and the processor 102 may have multiple instructions in the pipeline in different stages of execution. So it may have to adjust where the program re-starts once the exception processing is complete. Typically, the program counter points two instructions ahead of the currently-executing instruction. Processor 102 automatically saves the current program counter (PC) into a banked register at the beginning of exception processing, and then loads the PC with the exception vector. The specific vector is determined by the exception type. Each vector only provides space for one instruction word, e.g., a branch instruction to the full exception handler, except the FIQ entry which is the last vector entry. Because the FIQ entry is at the end of the list, the exception handler can occupy successive instruction words without needing to branch so FIQ's get the fastest possible servicing.
[0024] After exception processing, the PC must be reset. The exception handler may need to account for the effects of the pipeline by “backing up” the saved PC value by one or more instructions. E.g., the prefetch abort exception is invoked when the processor attempts to execute an instruction that could not be (pre-) fetched. By the time the invalid instruction is being “executed”, the PC has advanced beyond the instruction causing the exception. On exiting the prefetch abort exception handler, the system software must re-load the PC back one instruction from the PC saved at the time of the exception.
[0025] The FIQ is the last entry in the ARM7TDMI vector table so exception processing can begin without requiring a branch. Five “scratch” registers (R 8 -R 12 ) are banked and available to the exception handler. FIQ exception handlers are preferably written so the registers are not stacked and un-stacked, e.g., to avoid the consequential and inherently slow memory accesses.
[0026] [0026]FIG. 2 represents an interrupt controller 200 . An interrupt input 202 receives interrupt requests from various “blocks” within the system, and these are processed into IRQ interrupts 204 and FIQ interrupts 206 . A core implementation, such as PALMBUS by Palmchip Corporation (San Jose, Calif.) will include bus interface signals 208 and a bus interface 209 . A system clock 210 and a reset 212 are brought in from the processor core. A set of synchronizers 214 receives the interrupt sources. A mask register 216 programmably blocks selected interrupt sources. A prioritizer 218 is connected to a preamble enable 220 . A preamble instruction 222 and a vector from an interrupt vector instruction table 224 are combined in a block 226 and issued as an IRQ instruction 228 . An ISR instruction 230 is generated from the interrupt vector instruction table 224 .
[0027] The interrupt controller 200 centralizes all interrupt handling. It preferably includes programmable interrupt masks to independently enable or disable each interrupt source, and one to globally disable all interrupts. It further includes an interrupt vector control that automatically decodes the highest-priority interrupt for presentation of a programmed interrupt vector to the processor.
[0028] A cascaded interrupt structure is implemented with a two-level interrupt masking structure. A first masking level exists within the interrupt source itself. If any of the interrupt source's interrupt status bits are set and their corresponding interrupt enable bits are set, its interrupt is asserted. The source interrupt can be incapacitated by disabling all the interrupt bits within the interrupt source. A second interrupt masking level is implemented with the interrupt controller 106 . Each interrupt from different interrupt sources may be enabled or disabled, or a global disable may be enforced. All interrupts are cleared at the interrupt source level since they cannot be cleared in the interrupt controller.
[0029] The interrupt controller 106 preferably includes a global-disable control bit for use when a critical portion of program code is executing. In such a case, all interrupts must be disabled so the processor will not be interrupted out before that program code completes. Such global disable is preferably independent of individual interrupt masks so the firmware does not need to save and restore the mask states. Not having to save and restore the mask states saves both time and program code, and thus reduces interrupt latency when the global-disable is lifted.
[0030] Interrupt vectoring preferably uses a fixed-priority interrupt vector table. A vector priority is provided for each of the FIQ and IRQ interrupts 128 and 130 . The FIQ interrupt 128 always has a higher priority than the IRQ interrupt 130 in the ARM7TDMI processor 102 .
[0031] Interrupt vectoring of the IRQ and FIQ interrupts is critically remapped from memory space, e.g., memory 104 , to register space in the system control interrupt source.
[0032] Table I lists the registers that were assigned in a prototype of the interrupt controller 106 that was built. This implementation worked with a different set of interrupt sources than is shown in FIG. 1. Each register provides as many as thirty-two accessible bits, i.e., four 8-bit byte memory addresses.
TABLE I REGISTER SUMMARY addr register description CONTROL AND STATUS REGISTERS 00 INTRAW 04 INSTAT interrupt status 08 INTENA global interrupt enable 0C INTDIS global interrupt disable 10 INTMASK interrupt masks 14 CURINT current interrupt VECTOR INSTRUCTION REGISTERS 18 IRQINST IRQ instruction vector 1C FIQINST FIQ instruction vector 20 ISRINST ISR instruction vector PRIORITY DISABLE REGISTERS 30 PRIDISCFG priority disable configuration 34 PRIDISINST priority disable instruction PREAMBLE REGISTERS 40 PACFG preamble configuration 44 PAINST preamble instruction FIQ VECTOR INSTRUCTION REGISTERS 50 SVOINST0 54 SVOINST1 IRQ VECTOR INSTRUCTION REGISTERS 60 DCINST DC instruction vector 64 ATAINST ATA instruction vector 68 MACINST MAC instruction vector 6C SERINST serial instruction vector 70 UARTINST UART instruction vector 74 PCMCINST PCMCIA instruction vector 78 MTRINST motor instruction vector 7C TMRINST timer instruction vector 80 WDINST WD instruction vector 84 DEBGINST debug instruction vector
[0033] An interrupt status (INTSTAT) register includes FIQ interrupts SVOINT 0 and SVOINT 1 (bit 1 , bit 0 ), and its bits 2 - 11 are IRQ interrupts. The interrupt status bits for both types are arranged in the order of priority in the INTSTAT register. SVOINTO has priority over SVOINT 1 in the case of FIQ interrupts. For the IRQ interrupts the priority decreases from LSB (bit 2 ) to MSB (bit 9 ).
[0034] Each IRQ interrupt is associated with an instruction, stored in its respective 32-bit instruction register. When an IRQ interrupt is asserted, the ARM7TDMI processor 102 branches to the IRQ vector, address:0000.0018. When such address is remapped to register space using a REMAPIRQ bit in a system control interrupt source 120 , the instruction executed from the IRQINST register is taken from the IRQ vector table. Executing the instruction stored in the table saves interrupt decode time before the particular interrupt service routine (ISR) begins.
[0035] An interrupt service routine preamble takes advantage of the ARM7TDMI processor's ability to run two instruction sets, ARM 32-bit instructions, and Thumb 16-bit instructions. The switch between the two instruction sets requires that the firmware executes the BX instruction. In order to save program code space, as much program code as possible is run in Thumb mode. But, the ARM7TDMI naturally switches to ARM execution when an interrupt is received. Thus, every ISR generally needs a few instructions to put the processor in Thumb mode. Because this program code is common, and is not actually part of the ISR, it is referred to as an ISR preamble.
[0036] The PACFG register facilities in the interrupt controller 106 allow the execution of a preamble before each ISR. This saves program code space by not duplicating the preamble program code for each ISR. If the current interrupt's corresponding preamble enable bit is set in the PACFG register, the contents of the PAINST register are placed in the IRQINST register. If the PACFG bit is reset, the current interrupt's vector instruction is placed in the IRQINST register.
[0037] [0037]FIG. 3 represents interrupt vectoring with the ISR preamble enabled. An interrupt controller 300 includes a set of interrupt status registers 302 , a set of 32-bit instruction registers 304 , a preamble configuration (PACFG) register 306 , a preamble instruction (PAINT) register 308 , an IRQ instruction (IRQINST) register 310 , a preamble code register 312 , an ISR instruction (ISRINST) register 314 , an exception code register 316 , and an FIQ instruction register 318 . A particular prototype unit that was constructed had a dedicated set of interrupt status registers 321 - 331 , with register 321 being the highest priority. It also had a matching set of 32-bit instruction registers 332 - 342 .
[0038] If the preamble enable bit in PACFG register 306 of the highest-priority active interrupt is set, the instruction in the PAINT register 308 is executed. The instruction stored in a vector instruction table is generally a branch to the preamble program code. After execution of the preamble program code, firmware should branch to the ISRINST register 314 address. The ISRINST register 314 includes the vector instruction for the current interrupt, which is generally a branch to the interrupt ISR.
[0039] Because a higher-priority interrupt may occur between the execution of the ISR preamble and the execution of the corresponding ISR program code, the contents of ISRINST register 314 are preserved from the time the IRQINST register is read to the time the ISRINST register 314 is read. The ISRINST register is updated immediately thereafter.
[0040] [0040]FIG. 4 represents interrupt vectoring with the ISR preamble disabled. An interrupt controller 400 includes a set of interrupt status registers 402 , a set of 32-bit instruction registers 404 , a preamble configuration (PACFG) register 406 , a preamble instruction (PAINT) register 408 , an IRQ instruction (IRQINST) register 410 , an ISR instruction (ISRINST) register 414 , an exception code register 416 , and an FIQ instruction register 418 . A particular prototype unit that was constructed had a dedicated set of interrupt status registers 421 - 431 , with register 421 being the highest priority. It also had a matching set of 32-bit instruction registers 432 - 442 .
[0041] If a preamble enable bit in the PACFG register 406 for the highest-priority active interrupt is not set, the interrupt's instruction from the vector instruction table is placed in the IRQINST register 410 , allowing firmware to branch directly to the interrupt's ISR program code. In this case, the contents of IRQINST and ISRINST registers 410 and 414 are identical. Without preamble execution, the IRQINST register 410 will change whenever a higher-priority interrupt is asserted. However, once the interrupt has been read the processor enters the IRQ mode and does not exit until the interrupt is completely serviced.
[0042] Interrupt servicing may be done without hardware assistance by disabling the vector remapping (addresses 0000.0018 and 0000.001C) in the system control interrupt source 120 . ISR execution begins from a read-only memory ROM address if a REMAPRAM bit in the system control interrupt source 120 is ‘0’, or from internal memory if REMAPRAM is ‘1’.
[0043] It may not desirable to re-map the internal memory to the vector addresses (0000.0000), but an ability to modify the interrupt vectors without hardware priority decoding is needed. With vector remapping enabled, all interrupts can be serviced from a common routine by disabling priority decode for all interrupts, e.g., in the PRIDISCFG register. Thus, all interrupts will be serviced by the instruction written to the PRIDISINST register.
[0044] The preamble may be used for selective execution of the preamble program code. After preamble program code execution, ISR execution will begin with the PRIDISINST instruction for all interrupts.
[0045] The priorities of interrupts are controlled by hardware and cannot be changed with software in this particular implementation. However, some priority modification is allowed, if a few interrupt priorities need to be lowered. The IRQ interrupt priorities can be modified, the FIQ interrupt priority cannot. The hardware vectoring of an IRQ interrupt whose priority needs to be changed can be disabled by setting the corresponding bit in the PRIDISCFG register. If an interrupt's PRIDISCFG bit is set, that interrupt gets the lowest priority. The priority of all the other interrupts remains unchanged. When the highest-priority interrupt asserted has its PRIDISCFG bit set, PRIDISINST register is mapped to the IRQINST register. This will occur only if no other interrupt is set.
[0046] If multiple interrupt priorities are to be changed, firmware can use a combination of hardware-determined and firmware-determined priorities. The hardware priority decode is used for higher-priority interrupts and firmware is used to prioritize the rest of the interrupts. Firmware priority is selected by setting the PRIDISCFG bits of the highest-priority interrupt to be modified and of all interrupts which will have a lower priority.
[0047] For example, the priority of interrupt- 2 can be moved immediately below that of interrupt- 4 . To do this, the PRIDISCFG bit of interrupt- 2 is set; because the priority of interrupts- 5 through - 9 are to be below that of interrupt- 2 , their PRIDISCFG bits are also set. If interrupts- 0 , - 1 , - 3 or - 4 are asserted, a hardware priority decoder can map the highest-priority interrupt to the IRQINST register. If interrupt- 2 or interrupts- 5 through - 9 are asserted, the hardware priority decoder maps the PRIDISINST register to the IRQINST register. The PRIDISINST ISR reads the INTSTAT register and checks bit- 2 , then bits- 5 through - 9 to determine the interrupt source. It then calls the appropriate interrupt handling routine. If the priority decode for the lower-priority interrupts 5 - 9 were not disabled, interrupt- 2 would have a lower priority than interrupts 5 - 9 .
[0048] Such firmware priority decoding is less efficient than full hardware decoding. But hardware priorities can still be used for fast interrupt service, while providing for the other interrupt priorities to be user-defined.
[0049] Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that this disclosure is not interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that all appended claims be interpreted as covering all alterations and modifications as falling within the true spirit and scope of the invention.
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A interrupt controller includes specialized interfaces and controls for ARM7TDMI-type microcontroller cores. Such sends interrupt vectors and IRQ or FIQ interrupt requests to the processor depending on particular interrupts received. Wherein, THUMB program execution is more economical with program code space, and an interrupt service routine preamble is coded in ARM program code to cause a switch to THUMB program execution. The interrupt service routine preamble is shared amongst all the interrupt service routines to further economize on program code space.
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BACKGROUND OF THE INVENTION
The invention relates to a spindle device for adjusting the height of and aligning tracks on a substructure, having a transverse cantilever which is fixed to an elongate nut adjustable in height on a height adjustment spindle and which engages under the rails.
In the height adjustment and alignment of track grids for solid carriageways, it is not only necessary to adjust the rails to the correct height, but also to be able to bank these to some extent on bends, to which end the track grid needs to be tiltable. In a device disclosed in DE 197 671 C2 for the height adjustment and temporary support of rails, it is therefore provided that the rails bear on a bearing edge, so that when the track grid is more raised on one side than the other, as occurs at bends, the rails can tilt accordingly on their support. In this case, however, there is a risk that the vehicle may slip off sideways, and especially the height adjustment device provided in this case, with opposing displaceable wedges, is not suitable to effect the necessary horizontal displacement also required in aligning the track grids, since any horizontal displacement of one of the support wedges with the track would at the same time involve a change in the vertical position.
Spindle devices have proved advantageous in the height adjustment of track grids, although hitherto in principle two fully independent spindles have been required for height adjustment and horizontal displacement, the horizontal adjustment spindles involving the risk, in the case of large adjustments, of tilting of the vertical spindle, and hence the risk of inversion of the track.
SUMMARY OF THE INVENTION
The object of the invention is therefore so to form a spindle device for height adjustment and alignment of rails, in particular of track grids for solid carriageways, that a simpler and more reliable displacement is possible both in the vertical and in the horizontal directions without any adverse mutual interference.
To achieve this, it is proposed according to the invention that the transverse cantilever is formed as a horizontal spindle plate which is mounted pivotably about a horizontal axis on the elongate nut, and on which a slide provided with a clamping holding device for the rail foot is mounted displaceably by means of a second spindle device transverse to the height adjustment spindle.
With the configuration according to the invention, the transverse adjustment spindle no longer acts on the height adjustment spindle, so that unlike hitherto the height adjustment spindle is not pivoted out of its vertical position when a subsequent horizontal adjustment of the rail grid occurs. At the same time, the horizontal spindle plate mounted pivotably on the elongate nut provides a support for the rail, which can be adjusted to any desired angle where banked at a bend.
In an embodiment of the invention, it can be arranged that the slide consists of a ribbed plate provided with guide rails encompassing the horizontal spindle plate with a clamping hook and a conventional rail foot screw clamp. Thereby, a very simple mount of the rail is provided, which at the same time also permits a very simple horizontal adjustment device.
Thus according to a further feature of the invention, it can be provided that a rigid horizontal spindle penetrating a rest is fixed to the slide, in particular is welded thereto, and is displaceable along its longitudinal axis by means of adjusting nuts bearing on either side of the rest.
Furthermore, it is within the scope of the invention that the horizontal pivot joint of the horizontal spindle plate is fixable, which has the great advantage that during shaking or other forces acting laterally on a track grid, the support device cannot tip over.
In order to permit a simpler construction of the spindle device according to the invention after the casting of concrete, in an improvement of the invention it can be provided that the clamping hook can be removed above the ribbed plate, in particular in such a manner that the clamping hook is formed by a screw for a clamping plate overlapping the rail foot. This capacity of the clamping hook to be removed, in combination with a detachable fixing of the second spindle device both on the slide and on the horizontal spindle plate, permits simple removal of the support device, whilst a rigid hook makes it necessary at first to lower by the amount of projection of this hook.
If the second spindle device is so formed that it does not project above the sole of the rail foot, it may not need to be detachable, since this is provided purely in order that the support device according to the invention can be removed under the rail foot when this has been concreted in.
The length of the elongate nut mentioned, which is guided on the height adjustment spindle, is so selected that sufficient rigidity of the support is afforded, to which end it is advantageous if the elongate nut substantially overlaps the height adjustment spindle and only admits sufficient play for the usually necessary adjustment distances.
According to a further feature of the invention, support rails for the height adjustment spindles may be provided, which are fixed so as to rest on the track substructure and permit easier sliding in the longitudinal direction of the lower ends of the height adjustment spindles, so that differences due to thermal expansion can be compensated in the case of longer support periods.
In this case, it has been found particularly advantageous if the support rails are angled rails oriented opposite to one another with projecting bearing flanges for the height adjustment spindles, which prevents slipping off in the transverse direction. Here, oriented opposite to one another means that the angled rails face either both with their apertures outwards or both with their apertures inwards. U-shaped rails could also be used. The bearing flanges then abut in one case the height adjustment spindles on the inner face and/or on the outer face.
Further advantages, features and details of the invention will appear from the following description of an embodiment and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a view of a spindle device according to the invention with a rail supported thereon of a track grid (not otherwise shown) in a tilted position, as occurs in track bends with a banked portion,
FIG. 2 an enlarged detail of the pivot joint for the horizontal spindle plate in the direction of the arrow 11 in FIG. 1 ,
FIG. 3 a section along the line III-III in FIG. 1 ,
FIG. 4 a cross-section through the horizontal spindle plate,
FIG. 5 a view corresponding to FIG. 1 of a modified spindle device with removable hook for the rail foot and a modified configuration of the pivot joint,
FIG. 6 a plan view of the arrangement according to FIG. 5 without rail,
FIG. 7 a view of FIG. 5 in the direction of the arrow VII in FIG. 5
FIG. 8 a view from outside in the direction of the arrow VIII in FIG. 5 .
FIG. 9 is a cross-sectional plan view along the line IX-IX in FIG. 5 with the slides and the rail foot of the rail being depicted by phantom lines; and
FIG. 10 is a detail elevation showing the height adjustment spindle supported on a U-shaped support rail.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 , at 1 , the upper face of a track substructure can be seen, over which reinforcement rods 2 are to be seen, which will be embedded during subsequent casting. On the substructure 1 is supported a height adjustment spindle 3 , on which an elongate nut 4 is guided. By rotating the spindle e.g. by means of its hexagonal head 5 , the height of the elongate nut can be adjusted, a horizontal spindle plate 7 being fixed to the nut via a hinge device 6 . On this horizontal spindle plate, a slide 8 is mounted so as to be displaceable transversely, the slide comprising a ribbed plate 9 with a clamping hook 10 and a conventional rail foot screw clamp 11 for fixing the rail foot 12 of a rail 13 . The rail 13 is in this case a rail of a track grid with sleepers (not shown) connecting the rails. Spindle devices according to the invention are disposed at intervals along both rails. For horizontal adjustment of the track grid, a horizontal spindle 14 is used, which is fixed to the ribbed plate, is welded thereto in the example shown at 15 , and which penetrates a rest 16 of the horizontal spindle plate. By means of adjusting nuts 17 on the horizontal spindle 13 , adjustment in the longitudinal direction of the horizontal spindle is possible, i.e. in the desired horizontal transverse adjustment direction of the track grid, without this transverse adjustment having any effect on the position of the height adjustment spindle.
The guide rails 18 encompassing the horizontal spindle plate 7 are fixed laterally on the ribbed plate 8 , as can be seen in particular from FIG. 4 , the guide rails in the example shown consisting of two parts screwed together. These form the slide guide proper.
The horizontal spindle plate 7 is welded to two sleeves 19 , which are mounted on a pivot bearing bolt 20 of the pivot joint 6 . Between these sleeves is a further sleeve 21 , which is welded to the elongate nut 4 on the spindle 3 . To these sleeves 19 and 21 , plates are welded, which are provided with slots 24 , so that a certain degree of pivoting can take place, as is necessary for the purpose of pivoting of the horizontal spindle plate at banked portions of the track grid. The threaded spindle 25 with its head 26 and a nut 27 permits clamped locking of the plates 22 and 23 relative to one another, so that the pivot joint 6 is locked. This locking of the pivot joint after alignment has taken place has the critical advantage that when a track grid is subjected to lateral forces, it cannot fall over. For such locking, obviously a quick tightener could alternatively be used.
FIGS. 5 to 8 show a second embodiment of a spindle device according to the invention which differs from that in FIGS. 1 to 4 in essentially two points. On the one hand, the hook 10 of the ribbed plate 8 is replaced with a screw 10 a , which presses a clamping plate 10 b on to the rail foot 12 . This permits removal of the hook formed by these two parts 10 a and 10 b , in which case a lower supplementary plate 10 c may be provided, which must be slightly lower than the height of the rail foot 12 , so that after embedding of the aligned track grid with concrete, the ribbed plate 8 with the remaining parts of the spindle device can be easily removed to the left, without the need for previous lowering by the projection height of the hook 8 , as in the embodiments according to FIGS. 1 to 4 . According to this removability of the hook 10 a , 10 b , 10 c , the second spindle device with the horizontal spindle 14 is to be fixed both detachably to the slide with the ribbed plate 8 and by means of the screw 28 detachably to the horizontal spindle plate 7 .
Furthermore, instead of the spaced plates 23 with intermediate sleeves and support members, a solid block part 23 a is provided, which is mounted pivotably and fixably between the cheeks 22 by means of the threaded spindle 25 with its head 26 and the nut 27 .
At 30 , an angled rail can be seen, whose horizontal flange 31 is fixed to the track substructure, whilst the upward-projecting flange 32 forms an abutment for the height adjustment spindle 3 . To the left and right of the track grid, these angled rails are disposed in reverse, so that the upward-projecting flange respectively abuts the inner face of the height adjustment spindle 3 . The upward-projecting flange thus prevents displacement of the support device in the horizontal direction to the left or right, whilst the horizontal flange forms a support rail for the bulky lower end of the height adjustment spindle 3 , so that this can slide better in the axial direction of the track if relatively high temperature differences and corresponding lengthening of the track necessitate such displacement during the support period. This avoids complex longitudinal adjustment devices on the individual spindle devices, such as have been provided hitherto in the prior art.
As previously noted herein, it is deemed particularly advantageous if the support rails 30 are angled rails oriented opposite to one another with projecting bearing flanges 32 (upward projecting flange) for the height adjustment spindles 3 , which prevents slipping off in the transverse direction, as depicted, for example, in FIG. 9 . Also, as mentioned, U-shaped rails 30 ′ having a pair of upward projecting flanges 32 ′ could also be used, as shown, for example, in FIG. 10 .
Alternatively, the rails may have U-shaped profiles.
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Spindle device for the height adjustment and alignment of tracks on a substructure, having a transverse cantilever which is fixed to an elongate nut adjustable in height on a height adjustment spindle and which engages under the rail and which is formed as a horizontal spindle plate which is mounted on the elongate nut pivotably about a horizontal axis and on which a slide provided with a clamping mount device for the rail foot is displaceable by means of a second spindle device transverse to the height adjustment spindle.
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FIELD OF THE INVENTION
The present invention relates generally to a sash window with a guide assembly. Particularly, the present invention relates to a double-hung sash window wherein the window sash can be pivotally titled out of the window frame. More particularly, the present invention relates to a double-hung sash window having a guide assembly configured to guide the window sash in the jamb channel of the window frame and to secure the window sash to the window frame when the window sash is titled out of the window frame.
BACKGROUND OF THE INVENTION
It is known to provide a window for a home (or other building) with a window frame having rigid extrusions made from vinyl or other plastics), wood, aluminum, or other applicable materials and is used in combination with a window sash which may be made from wood, vinyl, aluminum, or other applicable materials. Generally, windows of this type include a “double-hung” window sash that is guided in a jamb channel (or jamb liner) of the window frame so that it is slidable relative to the window frame.
It is also known in a “double-hung” window base to provide the window sash with two pivot points, typically at the base of the window sash, to allow the window sash to be pivoted or “tilted” out of the window frame so that the exterior of the window sash can be accessed (i.e. for washing, painting, and/or repair) from the interior of the home or building.
In such known windows, counter-balance systems have been used to hold the window sash in an open position or closed position. Such known systems may include a counter-weight or spring balance assembly of some kind (i.e. that may operate in conjunction with an “interference” between the window sash and the jamb channel of the window frame). Typically, spring balance assemblies are enclosed in the jamb channels on each side of the window sash.
However, a problem encountered with conventional windows having a tilt-out window sash is construction of a suitable mechanism for the retention of the end of the counter-balance spring assembly that must be removably secured to the window sash (to allow “tilting” out). While the window sash may be tilted out of the frame (or may be completely removable), it is desirable that the window sash (which otherwise may move within the jamb channel from an open position to a closed position) not be movable within the jamb channel once tilted out (or when its full weight is not available to offset the pull of a spring balance assembly).
In windows that employ an “interference” counter-weight or spring-balance assembly, for example, including a balance shoe assembly with a balance “shoe” slidable in the jamb channel and engageable with the window sash (i.e. moving with the window sash when it is engaged), it is desirable that when tilting the window sash, the balance shoe assembly be retained in a fixed position within the jamb channel.
Locking mechanisms such as a positive locking arrangement for a balance shoe assembly are known. However, such known balance shoe assemblies typically require a plurality of parts, which makes them more difficult or costly to manufacture and assemble. Moreover, such known balance shoe assemblies typically do not provide for convenient yet secure removal of the window sash from the window frame.
Accordingly, it would be advantageous to provide a sash window with a guide assembly that includes a minimal number of parts and yet provides an adequate holding force when the window sash is tilted out. It would also be advantageous to provide a guide assembly in the frame of a balance shoe assembly that is simple and inexpensive to manufacture and assemble. It would further be advantageous to provide a balance shoe assembly that retains a sash pivot pin adequately when the sash is in the tilted out position, for example, in the balance shoe assembly, but still allows easy disengagement of the sash pivot pin from the balance shoe assembly and that also allows for removal of the window sash from the window frame. It would be desirable to provide for a sash window with a guide assembly providing at least some of these and other advantageous features.
SUMMARY OF THE INVENTION
The present invention relates to a guide assembly for translationally and pivotally mounting a window sash to a window frame providing a window jamb having a jamb channel. The guide assembly includes a housing configured for translating movement within the jamb channel. The guide assembly also includes a sash pivot configured to be coupled to the window sash. Further, the guide assembly includes a locking cam rotatably coupled to the housing. The locking cam includes a sash pivot retaining region. The locking cam also includes a surface configured to engage the jamb channel when the sash pivot is rotated to a first position.
Another exemplary embodiment of the invention also relates to a window. The window includes a window frame having a jamb channel and a window sash movable relative to the window frame. The window further includes a shoe housing including a sliding surface for guiding the housing in the jamb channel. The window also includes a sash pivot configured to be coupled to the window sash. Further still, the window includes a locking cam rotatably coupled to the shoe housing. The locking cam includes a sash pivot retaining region and the locking cam is configured to rotate substantially with the sash pivot. The locking cam includes a locking surface configured to engage the jamb channel when the sash pivot is rotated to a first position.
Still another exemplary embodiment of the invention further relates to a locking sash shoe for slidably and pivotably mounting a window sash to a window jamb, the window jamb having a jamb channel. The sash shoe includes a shoe housing with a sliding surface for guiding the housing in the jamb channel. The sash shoe also includes a sash pivot configured to be coupled to the window sash. The sash shoe also includes a locking cam rotatably coupled to the shoe housing. The locking cam includes a sash pivot retaining region. The locking cam is configured to rotate substantially with the sash pivot. The locking cam includes an integrally formed locking surface configured to engage the jamb channel when the sash pivot is rotated to a first position.
BRIEF DESCRIPTION OF THE DRAWINGS
The exemplary embodiments of the present invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like elements, in which:
FIG. 1 is a perspective view of a double-hung tilt-out window showing the bottom sash in the closed position.
FIG. 2 is a perspective view of a double-hung tilt-out window showing the lower sash in a partially open and partially tilted out position.
FIG. 3 is a side elevation view of the sash pivot pin engaging a balance shoe assembly.
FIG. 4 is an exploded perspective view of a balance shoe assembly and the sash pivot pin.
FIG. 5 is an elevational view of the balance shoe assembly.
FIG. 6 is a cross-sectional view of the balance shoe assembly and sash pivot pin taken along the line 6 — 6 in FIG. 5 .
FIG. 7 is an elevational view of the balance shoe assembly showing the window sash in a partially tilted out position.
FIG. 8 is an elevational view of the balance shoe assembly showing the window sash in the fully tilted out position.
FIG. 9 is a cross-sectional view of the balance shoe assembly engaged with the sash pivot pin taken along the line 9 — 9 in FIG. 8 .
FIG. 10 is a cross-sectional view of the balance shoe assembly engaged with the pivot pin taken along the line 10 — 10 in FIG. 8 .
FIG. 11 is a cross-sectional view of the balance shoe assembly engaging the sash pivot pin and showing the spring retainer flexing as the sash pivot pin enters the sash pivot pin retaining region.
FIG. 12 is a cross-sectional view of the balance shoe assembly similar to FIG. 11 but showing the sash pivot pin retained in the pivot pin retaining region and further showing the spring retainer retaining the sash pivot pin.
FIG. 13 is a cross-sectional view taken along the line 13 — 13 in FIG. 12 and showing the spring retainer stops engaging the jamb channel.
FIG. 14 is a cross-sectional view of the balance shoe assembly showing the spring retainer being flexed so that the pivot pin may be removed from the retaining region.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, a double-hung tilt-out window 10 is depicted. Window 10 includes an upper sash 12 and a lower sash 14 supported in a frame 16 . As shown partially in FIG. 3, frame 16 supports a jamb liner or jamb channel 18 that is configured to slidably support a guide assembly shown as a balance shoe assembly 20 (or a guide assembly). As depicted in FIGS. 1 and 2, balance shoe assembly 20 both engages and is slidably retained in jamb channel 18 . As depicted in FIG. 2, balance shoe assembly 20 on each side of frame 16 act as pivot points (which form an axis A—A for pivotal movement of lower sash) when a window sash (e.g. lower sash 14 ), is tilted out from the window frame, as is done to provide convenient access to the opposing side of the window (e.g. for repair, painting, washing, or other activity) from within an interior space without having to remove the window. According to an alternative embodiment, upper sash 12 may include a set of balance shoe assemblies similar to balance shoe assembly 20 , shown in FIG. 2 that are coupled to lower sash 14 . An engagement/disengagement device such as, but not limited to, a sliding latch may be installed at the top of sashes 12 and 14 to engage or disengage sashes 12 or 14 from jamb channel 18 . According to alternative embodiments, any of a wide variety of engagement/disengagement devices (e.g. spring-loaded latches, buttons, levers, etc.) may be used in the window.
Referring now to FIG. 4, an exploded view of balance shoe assembly 20 is depicted. Balance shoe assembly 20 includes a balance shoe housing 22 and a locking cam 24 . Locking cam 24 includes a wheel 26 having a plurality of serrations 28 and a hub 30 with a retaining region 32 . Retaining region 32 is configured to retain a sash pin 34 which is part of a sash pin assembly 36 . Sash pin assembly 36 includes a base 38 and sash pin 34 . According to a preferred embodiment, sash pin 34 may have a flange 40 and mounting holes 42 for mounting sash pin assembly 36 to a window sash, such as lower sash 14 . Hub 30 also includes a tang 31 extending opposite retaining region 32 and configured to prevent locking cam 24 from inadvertent disassembly with housing 22 .
According to a preferred embodiment, balance shoe assembly 20 is slidably captured within jamb channel 1 8 , as depicted in FIG. 9 . According to alternative embodiments, the balance shoe assemblies may be slidably retained in jamb channel by an interference fit. Also, in an alternative embodiment, the balance shoe assemblies may be configured to retain a balance spring within the balance shoe to counter balance the weight of a window sash. Alternatively, the balance shoe may be configured to be coupled to an end of a balance spring, to counter balance the weight of a window sash.
As shown in FIG. 2, balance shoe assemblies 20 are installed at opposite sides of sash 14 (and alternatively, sash 12 ). As shown in FIG. 3, sash pins 34 are mounted to sash 14 by fasteners (such as screws 37 ) and are supported by balance shoe assemblies 20 for pivotal rotation. By pivotal rotation, sash 14 is tiltable about longitudinal axis A—A (FIG. 2) defined by sash pins 34 on each side of sash 14 .
According to a preferred embodiment, to install a sash (such as sash 14 ) with a sash pin assembly 36 in a window frame 16 , sash 14 is held substantially horizontal and each sash pin 34 is slid through a corresponding slot 44 in housing 22 of balance shoe assembly 20 . Referring to FIG. 10, sash 14 and sash pin assembly 36 enter slot 44 in a direction depicted by arrow 46 . As sash 14 is installed, sash pin 34 contacts a retaining spring 48 (according to a preferred embodiment, spring 48 is integrally or unitarily formed with housing 22 ). Spring 48 is shown as a cantilevered flexible member, according to a preferred embodiment. According to alternative embodiments, the spring may be various other forms of a cantilevered flexible structure, or other configurations may be used. As shown in FIG. 11, retaining spring 48 is deflected in a direction 50 . When pin 34 is fully installed within retaining region 32 of locking cam 24 , spring 48 returns to an unflexed position, as depicted in FIG. 10 .
It should be noted that in an exemplary embodiment retainer spring 48 is integrally formed with housing 22 to provide the advantage of reduced complexity and simplified assembly, resulting in overall cost savings in the manufacturing of balance shoe assembly 20 . In an exemplary embodiment in which retainer spring 48 is integrally molded with housing 22 , the fabrication of housing 22 requires less complex tooling. For example, housing 22 may be a molded polymer (or other applicable material), the molding of which does not requires separate cores or paddles to be used, thereby resulting in simplified manufacturing processes.
Once pin 34 is retained in retaining region 32 , a movement of sash 14 in a direction, indicated by arrow 52 , as depicted in FIG. 12, causes pin 34 to engage retaining spring 48 and causes retaining spring 48 to flex in a direction indicated by arrow 54 . Retaining spring 48 includes stops that engage jamb channel 18 , as depicted in FIG. 13 . Stops 56 prevent retaining spring 48 from over-flexing and potentially breaking from housing 22 . Further, stops 56 prevent retaining spring 48 from substantial deflection, thereby aiding in the retention of pin 34 in retaining region 32 . To remove sash 14 from retaining pin 34 , a retaining spring 48 is pushed in a direction 58 , depicted in FIG. 14, by using a finger or a tool 60 that causes spring 48 to flex and thereby provide clearance for pin 34 to slide out of retaining region 32 in the direction indicated by arrow 59 .
When sash 14 is in the fully tilted up position, like that shown in FIG. 1, hub 30 of locking cam 24 is in the position shown in FIG. 5, whereby pin 34 is retained in hub 30 . In the fully tilted up position, sash 14 , engaged with balance shoe assembly 20 , may slide up and down while being retained within jamb channel 18 , as shown in FIGS. 5 and 6. As shown in FIGS. 5 and 6, serrations 28 do not interfere with, engage, or substantially prevent balance shoe assembly 20 from moving within jamb channel 18 when sash 14 is in the fully tilted-up position.
As depicted in FIG. 7, when sash 14 is tilted out of frame 16 , pin 34 causes hub 30 to rotate and causes locking or engagement surfaces, shown as serrations 28 , to engage jamb channel 18 , as shown in FIGS. 8 and 9. As sash 14 reaches the fully horizontal position, as shown in FIG. 8, balance shoe assembly 20 is prevented from moving (e.g., sliding) within jamb channel 18 because serrations 28 provide a frictional and interfering engagement with jamb channel 18 thereby preventing any movement either when an individual is working on sash 14 or when a user is removing sash 14 (as depicted in FIG. 14 ). Further, when sash 14 is in the position shown in FIG. 8, the pin may be removed from retention in hub 30 of locking cam 26 by deflecting retaining spring 48 as depicted in FIG. 14 . Spring 48 may be deflected by pressing using a finger or any appropriate tool, such as tool 60 .
According to a preferred embodiment, balance shoe assembly 20 may be manufactured from molded plastic. According to alternative embodiments, balance shoe assembly 20 may be made from materials, such as, but not limited to, metallic, polyester, nylon, composite materials, and other well known polymers. Further, it should be noted that balance shoe assembly 20 is configured for easy assembly because balance shoe assembly 20 includes two parts, housing 22 and locking cam 26 that interact with a sash pivot assembly 36 . Because of the limited number of parts and the ability of the parts to be manufactured through a molding process, balance shoe assembly 20 may be simply assembled and may be manufactured relatively inexpensively. Balance shoe assembly 20 described above may be suitably used in a variety of window/window frame arrangements including, but not limited to, any of a variety of sliding window arrangements. Alternatively, a plurality of different retainer spring arrangements may be provided within housing 22 to retain the pivot pin within housing 22 .
The method of assembly and/or use of the guide assembly, according to preferred and alternative embodiments, may be performed in various steps; any omissions or additions of steps to those steps disclosed, or any departure from the order or sequences of steps recited, should be considered to fit within the spirit and scope of the invention.
While the detailed drawings, specific examples, and particular formulations given describe preferred or exemplary embodiments, they serve the purpose of illustration only. The materials and configurations shown and described may differ depending on the chosen performance characteristics and physical characteristics of the window and frame, for example, the jamb channel or jamb liner may differ in geometry than that disclosed. As another example, the geometry of the locking cam and/or the balance shoe housing may be markedly different while providing the same structure and function as within the spirit and scope of the invention. The apparatus of the invention is not limited to the precise details and conditions disclosed. Furthermore, other substitutions, modifications, changes, and omissions may be made in the design, operating conditions and arrangements of the preferred embodiments without departing from the spirit of the invention as expressed in the appended claims.
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A guide assembly or balance shoe assembly for slidably and pivotably mounting a window sash to a window jamb is disclosed. The guide assembly includes a shoe housing having sliding surfaces that guide the housing in the jamb channel. A sash pivot is coupled to the window sash and a locking cam is rotatably coupled within the shoe housing. The locking cam includes a sash pivot that retains the sash pivot pin. The locking cam rotates substantially with the sash pivot and the locking cam has a locking surface that is configured to engage the jamb channel when the sash pivot is rotated to a first position.
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BACKGROUND OF THE DISCLOSURE
A wall mounted or room air conditioner/heat pump is typically constructed as an outer sleeve and a chassis (two pieces) which are adapted to be installed either in a window or through a wall opening. At one end, it is cosmetically attractive to extend into the room which is to be cooled or heated during operation. The opposite end is exposed to the exterior for heat rejection or heat pickup.
In accordance with known cooling operation, heat is taken from the room and rejected out through the back end of the cabinet or case through a condenser. This cabinet is normally described as a sleeve, referring to the surrounding rectangular metal container. The sleeve contains a chassis which can slide in and out of the sleeve. The bottom side of the chassis will be described hereinafter as the "pan." It is a pan especially in the sense that it collects liquid condensate. During the routine operation of the air conditioner, excess humidity in the room air is removed. This humidity is converted into condensate, collecting on a coil within the air conditioner and it is guided or directed by gravity, dripping onto the pan and towards the back end of the pan. It sometimes drips off the back end of the pan to the exterior of the building, when the condensate removal is excessive.
Certain problems arise from the dripping water. It incessantly keeps the surface areas below the window or wall opening wet. If the structure is wood construction, or if there is any area which is susceptible to accelerated rotting when wet, undue damage can arise as a result of the water flow. The possibility exists that the window casement or wooden framing may rot completely away and require extensive carpentry repair. Moreover, as the water runs down the side, even should the side of the building be water resistant, the water will collect pigments, and discolor the surface area. It can take on any color from a stained dirty brown to a green mold color, all to the detriment and harm to the building which is being air conditioned. It is with this problem, in the background that the present apparatus is set forth.
It is sometimes difficult to service such window or wall unit air conditioners. They are typically constructed so the chassis can be withdrawn into the room. If the room is at ground level, service personnel can approach from the exterior quite readily. If, however, the unit is mounted either high in a ground level room or in a multistory structure, gaining access to the exterior wall is quite difficult. Such access cannot be readily obtained without ladders or scaffolding. Accordingly, it is highly desirable that the condensate which travels on the gently sloping pan be guided to the exterior and directed away from the supporting wall and other structures so that condensate disposal is easily accomplished, preferably through a drain tube.
The present apparatus is a retrofit device which can be installed without requiring external access to the window air conditioning unit. It clips to a lip which is incorporated on the bottom exterior of the sleeve. For purposes of efficient heat rejection, there is a louvered or screened panel at the back end of the air conditioner. Heat rejection is caused by air flowing over the condenser and then through this panel. This panel is removed to expose the lip on the bottom exterior of the sleeve. The present apparatus clips to that lip and is therefore installed easily after withdrawing the window unit into the room. The unit can be quickly withdrawn from the fixed sleeve into the room, the louvered panel removed, the present invention installed on the outside edge (lip) of the sleeve, and thereafter the window air conditioner is repositioned in the sleeve opening, along with the louvered panel. The louvered panel secures the present invention in place.
The present apparatus, when installed, does not change the dimensions of the sleeve or unit, so that the unit is easily reinstalled into the same opening. For this reason, it is particularly helpful after easy installation to guide and direct the collected condensate away from the building. This reduces damage from rotting, mildew, or fungus on the building. It also avoids the unsightly stains. It further reduces building maintenance by avoiding the necessity of repainting and the like.
Patent references which set forth structures known heretofore include:
______________________________________Pat. No. Inventor______________________________________4,513,586 Jennings et al.4,416,327 Nakada et al.3,000,192 Mullin et al.4,766,738 Ebata3,724,233 Pugh, et al.______________________________________
The most material of the foregoing references is the '586 patent. This discloses a combination compressor support with a drain pan which has a drain bracket. It is used to collect and dispose of condensate from operation of the air conditioning equipment. In particular, it collects and diverts the condensate out through the protruding pan which is attached by a set of screws as detailed fully therein. A gusset 64 also functions as a mounting bracket and has a drain passage therethrough.
The apparatus of the present disclosure sets forth a mechanism which is affixed to the pre-existent window or wall air conditioning unit without requiring modification and the device is attached by latching into the sleeve lip just at the edge of the pan. The present apparatus has been summarized briefly above, but a better understanding of this apparatus will be obtained upon a review of the drawings which are incorporated below, and which relate to the detailed description set forth in the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a front view of the retrofit apparatus of this disclosure shown installed on the sleeve of a window air conditioning unit, with a portion broken away to show a drained opening therein; and
FIG. 2 is an end view of the retrofit apparatus of FIG. 1 showing clipping of this apparatus over a portion of the sleeve of the window air conditioning unit wherein installation is accomplished by hand, without any tools.
FIG. 3 is a perspective view of the apparatus in place on the sleeve of the air conditioning unit, showing an optional embodiment with two drains.
FIG. 4 is a rear perspective view of the apparatus in place on the sleeve of the air conditioning unit, showing an optional embodiment with two drains.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is first directed to FIG. 1 of the drawings where the numeral 10 identifies the retrofit apparatus of this disclosure installed on a window air conditioning sleeve 12. The air conditioning sleeve 12 is constructed to fit within an opening of a building (not shown) which supports the air conditioning unit with the heat rejection occurring out through the back end of the air conditioning sleeve. The air conditioning unit is constructed also with a louvered opening 14. This opening is covered with a grill or the like. A fan (not shown) within the air conditioning equipment blows hot air out through this opening, in cooling operation.
This opening 14 defines a marginal lip or area 16 which encircles the opening on the sides. Moreover, the opening 14 terminates at a lower edge 18 that is parallel to the bottom of the sleeve 20 as shown in FIG. 1. As will be observed, the retrofit accessory of the present disclosure has been partly broken way to provide better illustration of its installation on the air conditioning sleeve 12.
The present invention may be sized to fit various models of air conditioning units. Since these dimensions are fixed, the present apparatus may find ready adaptability for installation on a number of different types and models of air conditioning units. To this end, they are all handled in the same fashion so that installation is done in the same way. Therefore, this installation approach can be used for practically all such air conditioning units. Accordingly, the accessory of this disclosure is a water drainage accessory which releasably clips onto the sleeve in the fashion set forth below.
The accessory 10 is typically stamped out of sheet metal stock (or formed from plastic) which is painted or coated to prevent rust or decay. This forms a sheet metal trough. This is better shown in FIG. 2 of the drawings. There, the clip-on accessory has a back lip 22 which is creased at 24. It has a vertical member or top portion 26 extending below the crease 24. There is a bend, in the range of about 20 to 40 degrees, located at 28 which positions a front face 30 at about a 30° angle from the top portion 26. The front face at 30 is part of the trough which collects condensate as will be described. It is likewise bent at the bottom edge 31 to define a bottom 32. The bottom also supports a bent upstanding back wall 34. Going to FIG. 1 of the drawings, front walls created by the top portion 26 and front face 30 provide almost a continuous exposed area that supports the trough. Moreover, the trough extends to the rear so as to be located beneath the bottom of the sleeve 20. Assuming that the apparatus is formed of a sheet metal (or the like) stamping, it is formed with folded end walls such as the end wall 36 shown in FIG. 2. This is folded over in a transverse direction to close off the end of the trough. As necessary, a sealant such as silicon, or other caulking material, is placed in the corners around the end walls 36 to prevent leakage. If plastic, the end walls are molded in and sealing is not necessary. This assures construction of a leak-proof trough so that condensate is captured.
In the ordinary operation of the air conditioning unit, condensate is formed in the inside portions of the air conditioning unit and flows by gravity downwardly and accumulates in the back of the pan above the sleeve bottom 20. The units are constructed so that the unwanted condensate is directed by gravity on a gentle slope towards the rear of the air conditioning unit. Excessive condensate causes the water to drip onto and off the sleeve bottom 20. Moreover, that causes the water to be directed into the trough. It collects in the trough and is removed through an opening in the trough. For easy connection with a drain tube, the preferred embodiment 10 incorporates a drain hole. More specifically, an internal resilient material gasket 40 is glued or otherwise attached in the trough, though it is not necessary. It has a hole which aligns with an equal sized hole through the trough bottom 32. A similar gasket 42 may be located on the nether side, although it is not required. The gasket 42 supports a nipple 44 for easy attachment of a tubing hose or the like. Gasket 42 and nipple 44 may be combined into one piece, which can be plastic. The gaskets 40 and 42 are installed either with an adhesive or, alternately, with mounting screws. If screws are used, they preferably are pulled tight so that the resilient material comprising the gaskets 40 and 42 seals against leakage at that location. This provides a downward drain subsequently removing the condensate. As required, the drain just described can be located at two or three locations along the length of the apparatus.
For installation, it should be noted that the removable retrofit attachment 10 has different lengths in contrasting the top and bottom edges. The front face 30 is equal in length to the width of the air conditioning unit. This enables the back edge of the sleeve bottom 20 to be enclosed within the trough so that the trough extends slightly over the ends and captures that portion of the sleeve edge. By contrast, the louvered opening is shorter in width, and therefore the top portion 26 is shorter. It is shorter at each end to accommodate the marginal area 16. Moreover, this arrangement assures that the clipping action for attachment is easily accomplished. The air conditioning louvered opening has a specified width, and the back lip 22 which affixes the retrofit apparatus 10 is sized so as to be slightly less in linear dimension. It is installed simply by hand guidance to assure that the back lip 22 overhangs and captures the top edge at the louvered opening.
Once installed, the chassis can be repositioned into sleeve 12 through wall opening or window. While FIG. 2 shows the present apparatus protruding below, the scale of the present apparatus really does not add a cause for concern, namely, that the air conditioning unit will no longer fit. The present apparatus protrudes only about one-half inch (1/2") below the sleeve bottom 20; this is relatively small and is located away from the portions of the sleeve bottom 20 which rest on supporting frame work, either in the window or in the sleeved wall opening where the apparatus is installed.
When the device is installed, any excess condensate flows into the trough and is diverted away from the house or other structure to reduce damage. If sufficient clearance is available, the condensate can be dripped through the nipple 44. If clearance is poor, the condensate can be collected and delivered into a small tubing connected to the nipple for water removal. Once installed, it can be left indefinitely and may well outlast the air conditioning unit.
The trough is provided with some water capacity; that is, it can collect and hold a small quantity of water. There is always the risk of plugging at the drain opening, and to this end, the preferred embodiment is furnished with multiple drain openings to reduce the risk of total plugging and the consequential overflow. If plugging does occur, servicing the present apparatus can be easily accomplished by demounting it in the fashion described above. While the foregoing instrument is drawn to the preferred embodiment, the scope thereof is determined by the claims which follow.
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A clip-on retrofit drainage tray or trough is disclosed. The device has a full width tray fitting at the exposed back edge of a window unit or through-the-wall air conditioner, and is located just below the bottom of the sleeve to catch condensate. The dripping water is drained into the trough and out through a drain hole formed in the trough. The trough has an overhead clip attaching on a lip above the sleeve bottom.
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FIELD AND BACKGROUND OF THE INVENTION
My present invention relates to a microwave circuit with coplanar conductor strips.
An important application of such a circuit is in monolithic or hybrid microelectronics, such as for example interdigitated filters.
The electrical state of two coupled transmission lines functioning with transverse electromagnetic waves can be represented at any time by two propagation modes superimposed on each transmission line.
A first mode, called the even mode, is characterized by pairs of conductors with cophasal voltage and current values (E, I) in any cross-sectional plane of each line; a second mode, called the odd mode, is characterized by pairs of conductors whose voltage and current values (E, I) are in phase opposition in any such cross-sectional plane. In the case of a line produced by microstrip technology, i.e. constituted by conducting strips arranged on the same face of a dielectric substrate whose other face is covered by a conductive layer known as a ground plane, the phase velocity of one mode involving propagation between one conducting strip and the ground plane (even mode) cannot be equal to the phase velocity of a mode involving propagation between two adjacent conducting strips (odd mode). Thus, in the first case propagation takes place almost exclusively through the substrate and in the second case a significant fraction of the energy is propagated in air, so that the very presence of the substrate makes the propagation medium nonhomogeneous. As a result, the equivalent electrical diagrams of the coupled lines become very complex or can but roughly approximate the actual conditions.
Various solutions have been proposed for homogenizing the dielectric and consequently reducing the variation between the phase velocities of the different propagation modes.
The Podell coupler described in Microwaves Magazine, March 1974, pp. 58 to 62 decreases the phase velocity in the odd mode without modifying the phase velocity in the even mode. However, this type of coupler cannot be used for coupling above 8 dB.
The overlay coupler described in the publication of IEEE Transactions on M.T.T., vol. 18, No. 4, April 1970, pp. 222 to 228 requires a transfer of dielectric material to the circuit and is difficult to realize, owing to the complicated procedure required for identically repeating the technical characteristics of couplers of this type.
Another solution, described by B. Schiek, J. Kohler and W. Shilz in the report of the 6th European Microwave Conference of 14-17 September 1976, published by Microwave Exhibitions and Publishers, Ltd., Temple Gate House, 36 High Street, Sevenoaks, Kent, TN 13 15G, England, comprises compensating the phase-velocity divergence of the even and odd modes by a stepped line construction having two coupled line sections with substantially the same length but different coupling factors due to their different spacings. This solution has the disadvantage of requiring complex calculations for its realization and, furthermore, does not make it possible to obtain, in its application to a Schiffman cell, an operation of the device on a frequency band higher than one octave.
OBJECTS OF THE INVENTION
An object of my present invention is to obviate the disadvantages referred to hereinbefore and to provide a microwave circuit with coupled lines for which the phase velocities of the different modes are brought close together.
Another object of the present invention is the provision of improved microwave circuits with both broad-band and narrow-band coupled lines.
My invention further aims at greatly reducing the dimensions of such microwave circuits.
SUMMARY OF THE INVENTION
A microwave circuit according to my invention comprises a dielectric substrate with a flat face carrying on one area thereof a grounded metallic layer and on another area thereof a multiplicity of conductor strips framed by that layer and coplanar therewith. These conductor strips are part of one or more transmission lines which, pursuant to a feature of my invention, terminate at an edge of the substrate in an ungrounded central conductor which is coplanar with two flanking zones of the metallic layer.
Pursuant to another feature of my invention, a plurality of mutually coupled transmission lines formed by the aforementioned conductor strips each include at least one such conductor strip spacedly interposed between two bracketing conductor strips of another of these transmission lines, the bracketing conductor strips being conductively interconnected at both ends. The connection between at least one pair of these strip ends can be a short-circuiting wire jumping across the interposed conductor strip of the other line. Such a connection, however, can also be made with the aid of a short-circuiting transverse strip section.
In like manner, one or more ground strips can be spacedly interleaved with the conductor strips of the transmission line or lines, each such ground strip having two ends connected to the metallic layer either integrally or through a short-circuiting wire jumping across another strip.
BRIEF DESCRIPTION OF THE DRAWING
The above and other features of my invention will now be described in greater detail with reference to the attached drawing wherein:
FIG. 1 is a perspective view of an assembly of coplanar coupled lines according to my invention;
FIG. 2 is a face view of a microwave filter according to my invention;
FIG. 3 is a face view of another type of microwave filter according to my invention;
FIG. 4 is a face view of a directional coupling according to my invention;
FIG. 5 is a perspective view of a coplanar delay line according to my invention;
FIG. 6 is a similar view of another coplanar delay line according to my invention;
FIG. 7 is a perspective view of a Wilkinson T according to my invention; and
FIG. 8 is a similar view of a dividing T with two sections according to my invention.
DETAILED DESCRIPTION
Identical or equivalent elements in the various views of the drawing are given the same reference characters.
According to FIG. 1, a microwave circuit with coupled lines according to my invention comprises a dielectric substrate plate 1 on which there are provided two coupled transmission lines propagating a transverse electromagnetic mode. These lines comprise several conductor strips 2a 1 , 2a 2 , . . . 2a i and 2b 1 , 2b 2 , . . . 2b i framed by a common conductor 3. The partly cut-away metal layer serving as the grounded conductor 3 has an integral extension in the form of a strip 4 inserted between the two groups of line-forming strips 2a 1 etc. and 2b 1 etc.
The conducting strips 2a 1 --2a i , 2b 1 --2b i and 4 are parallel to one another and are separated by gaps whose widths depend, like the number and arrangement of the strips, on the radio-frequency characteristics of the circuit in question and consequently on the coupling factor desired between the several transmission lines.
The mutually parallel conducting strips of each group, which constitute with parts of the ground conductor 3 a transverse-electromagnetic (TEM) transmission line, are interconnected in pairs by conducting wires or jumpers 5 and by transverse strip sections 9 forming a short circuit; the free end of strip 4 is connected to the grounded conductor 3 by a similar jumper 10. All the conducting strips of the circuit can be produced by metallization, comprising for example a resistive coating of nickel and chromium and a conductive gold coating, the respective conductivities of nickel, chromium and gold being 16·10 6 Ω -1 ·m -1 , 6.5·10 6 Ω -1 ·m -1 and 49·10 6 Ω -1 ·m -1 .
In such a circuit, the various propagation modes existing between the conductor strips are of the TEM or quasi-TEM type and the practical realizations have shown that all the parasitic modes which can exist therein are at very low levels compared with the principal TEM mode, thus permitting the design of selective components as filters.
An example of an application of this type of microwave circuit with coplanar coupled lines according to my invention is given in FIG. 2 which shows an interdigitated microwave filter. This filter comprises six coupled transmission lines, generally designated 13, in addition to an input line 11 and an output line 12 respectively constituted by a central conductor 110 or 120 each flanked by two zones of ground conductor 3. To regulate the capacitances per unit length between the several lines and the capacitances per unit length between these lines and the common conductor, each TEM line 13 is constituted by two conducting strips 2a 1 , 2a 2 which are arranged on either side of a ground strip 4 integral with common conductor 3 and have free ends interconnected by a conducting wire 5 ensuring equipotentiality at locations remote from conductor 3 to which their opposite ends are joined. Central conductors 110 and 120 are seen to be substantially wider than any of the strips of lines 13.
FIG. 3 illustrates another embodiment of my invention constituting a very-wide-band interdigitated microwave filter with two transmission lines in addition to an input line 14 and an output line 15. Each of these transmission lines is constituted by four conductive strips 2a 1 -2a 4 and 2b 1 -2b 4 with free extremities interconnected by conducting wires 5 jumping across intervening ground strips 4. The strips 2a 3 , 2a 4 of one transmission line and 2b 3 , 2b 4 of the other transmission line are interleaved for coupling reasons. Similar interleaving exists between lines 14 and 2a 1 -2a 4 as well as between lines 15 and 2b 1 -2b 4 . Here again, the conducting wires 5 can be replaced by transverse strip sections forming a short circuit between free ends of neighboring strips of the same line, provided that ground strips 4 are foreshortened and linked with layer 3 by jumpers 10 as shown in FIG. 1.
By way of example, for a central pass-band frequency of 5.535 GHz and a bandwidth of 39.2%, the width of the conducting strips is between 100 and 200μ and the distance between these strips is between 100 and 200μ, giving as the overall dimensions of the filter approximately 11 mm by 6 mm.
FIG. 4 shows an application of my improved microwave circuit to a directional coupler with two coplanar transmission lines coupled together on the same dielectric substrate. An input channel 40 and a coupled channel 42 are located on one side of the circuit whereas a direct output channel 41 and a directional channel 43 are on the opposite side.
The transmission lines joining the input channel 40 to the direct output channel 41 on the one hand and the coupled channel 42 to the directional channel 43 on the other hand are constituted by the common grounded conductor 3 and by two ungrounded conductors bent into meanders 46 around three ground strips 4 integral with conductor 3. These ground strips extend alternately from opposite edges of a substantially rectangular cutout of layer 3, each such strip having a free end linked with that layer by a wire 10 jumping across transverse strip sections of the meandering conductors disposed in that cutout.
Each meander comprises two arms 44 and 45 constituted by interdigitated conducting strips 2a 1 , 2a 2 etc. and 2b 1 , 2b 2 etc. Two strips of one line bracketing a strip of the other line are integrally interconnected at one end and short-circuited by jumpers 5 at their opposite ends. The spacing of these arms from each other, and from the intervening ground strip 4, is seen to be substantially greater than the strip spacing within each arm.
By way of example, for a central operating frequency of 1.3 GHz, the width of the conducting strips is between 100 and 200μ and the distance between the strips is between 50 and 280μ, giving as the overall dimensions for the coupler approximately 6 mm by 6.3 mm.
A special case of a microwave circuit according to my invention is that comprising a single transmission line constituted by a plurality of interconnected conducting strips and a common conductor forming a meandering delay line as shown in FIG. 5. The delay line comprises an input termination 6, constituted by a central conductor 7 between two coplanar zones of the grounded conductor 3, an output termination 8 of similar shape, and mutually parallel conducting strips 2 alternately interconnected at opposite ends by short-circuiting strip sections 9. Conducting wires 10 connect the free ends of ground strips 4, bracketed by the interconnected strips 2, to the surrounding conductor 3.
FIG. 6 shows another embodiment of such a delay line in which the conducting strips 2 are interconnected, alternately at opposite ends, by short-circuiting wires 5 jumping across ground strips 4.
FIG. 7 shows a microwave circuit according to my invention designed as a Wilkinson T with an input line 73 of impedance 50Ω and two meandering line branches 71 and 72, of length λ/4 at the median operating frequency and impedance 70Ω terminating at a resistance 76 of 100Ω permitting matching with two output lines 77, 78 having an impedance of 50Ω. Input line 73 and output lines 77, 78 comprise respective central conductors 730, 770 and 780 each flanked by two zones of the grounded conductor 3 coplanar therewith. The two line branches 71 and 72 of length λ/4 are constituted by conducting strips 2 inserted between ground strips 4 integrally joined at one end to conductor 3. The conducting strips 2 are alternately interconnected at opposite ends by short-circuiting strip sections 9 whereas strips 4 are grounded at their free ends by respective wires 10 jumping across these transverse sections.
In this embodiment, the two meandering line branches 71 and 72 could also be of the form described with reference to FIG. 6.
By way of example, for a central operating frequency of 0.8 GHz, the width of the conducting strips in the Wilkinson T of FIG. 7 is approximately 100μ and the distance between two conducting strips is approximately 110μ, so that the overall dimensions of each section 71 and 72 is L=4.16 mm by L'=4.13 mm.
FIG. 8 shows another embodiment of a microwave circuit according to my invention in the form of a double-section dividing T. If this coplanar circuitry were produced in some other manner, e.g. by microstrip technology, it would have unduly small dimensions on account of the high central operating frequency. This dividing T has an input 81 in the form of a coplanar line of impedance 50Ω, constituted by a central conductor 82 flanked by two zones of the grounded conductor 3, divided into two coplanar branches 83 and 84 of impedance 80Ω.
The two line branches 83 and 84 are interconnected by a resistor 85 of 76Ω after a distance L equal to a quarter wavelength λ/4 at the median operating frequency of the T. These branches are respectively extended by two coplanar lines 86, 87 of impedance 60Ω which are short-circuited by a resistor 88 of 268Ω after another distance L=λ/4 before being continued by two coplanar output lines 89, 90 of impedance 50Ω. Line strips 83, 84 and 86, 87 bracket respective ground strips 91, 92 each linked at both ends with metal layer 3 by jumpers 10.
By way of example, for a central operating frequency of 14.5 GHz, the width of the conducting strips is between 92 and 155μ and the distance separating them is between 100 and 162μ, the length L being of the order of 2.3 mm.
In all the represented embodiments, one of the advantages of my invention is the availability of circuits of greatly reduced dimensions compared with those produced by three-plate or microstrip technology.
Another advantage of my invention is that of providing weak or strong couplings, depending on whether wide-band or narrow-band filters are to be used, as a result of the interdigitation of the line strips and the grounded conductor.
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A microwave circuit has a flat dielectric substrate with one face carrying a grounded metallic layer partly broken away to leave room for a multiplicity of conductor strips coplanar therewith which form part of one or more transmission lines having input and output ends each comprising an ungrounded strip portion flanked by two zones of the grounded layer. Electrical continuity between separated portions of that layer, and/or between nonadjacent conductor strips, is established by short-circuiting wires jumping across intervening strip sections. With coupled transmission lines operating with different modes of propagation, this structure substantially equalizes their respective phase velocities.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/572,561, filed Oct. 02, 2009, now U.S. Pat. No. 7,850,824, which is a divisional of U.S. patent application Ser. No. 11/548,454, filed Oct. 11, 2006, now U.S. Pat. No. 7,597,782, which is incorporated by reference.
BACKGROUND
Generally, the paper manufacturing process employs a machine that systematically de-waters a pulp slurry which consists largely of cellulose wood fibers, along with various chemical additives used as fillers and functional components of the paper or paper products. The pulp is prepared from various species of wood, by basically either of two pulping methods: chemical digestion to separate the cellulose fibers from lignin and other natural organic binders, or by mechanical grinding and refining. The resulting cellulose fibers are used in the manufacture of paper products whereby the pulp is supplied to a paper machine system, slurried in water to various solids levels (consistency), and ultimately diluted to about 0.5-1.0% solids for subsequent de-watering to form a sheet of paper. The low consistency of solids is necessary in order to facilitate fast drainage on the former while achieving proper fiber-to-fiber contact and orientation in the sheet. De-watering begins on the former, which is a synthetic wire or mesh that permits drainage to form a wet-web.
The web is then transferred into the machine press section and is squeezed between roller nips and synthetic press felts (predominantly comprised of nylon) to further remove water, and then through a dryer section comprised of steam-heated roller cans. Finally, the sheet is wound onto a reel. Other process stages can include on-machine surface sizing, coating, and/or calendaring to impart functional paper characteristics.
Generally, the wet-web is approximately 20% solids coming off of the former, 40% solids after leaving the press section, and about 94-97% solids (3-6% moisture) as the paper on the reel. Various chemical compounds are added to the fiber slurry to impart certain functional properties, to different types of paper. Fillers such as clay, talc, titanium dioxide, and calcium carbonate may be added to the slurry to impart opacity, improve brightness, improve sheet printing, substitute for more expensive fiber, improve sheet smoothness, and improve overall paper quality. Also, various organic compounds are added to the fiber slurry to further enhance paper characteristics. These include: sizing agents (either acid rosin, or alkaline AKD or ASA) to improve sheet printing so the ink doesn't bleed through the sheet, starch for internal fiber bonding strength, retention aids to help hold or bind the inorganic fillers and cellulose fines in the sheet, brightening compounds, dyes, etc. Therefore, as the sheet is de-watered on the paper machine, many types of deposits can result on the papermaking equipment. These deposits result from the chemicals used in the process, along with the natural wood compounds that are not thoroughly removed from pulping processes, or from inclusion of recycled fiber in the pulp slurry, and as a result of water re-use.
The primary function of the press-felt fabrics (other than a means of sheet conveyance) is to aid in the de-watering process of the wet-web. The press felts act like blotters or sponges that receive water that is expressed from the web by the pressure of the roller nips. On most modern paper machines, the water is then removed from the press felts by vacuum elements in the press, consisting of the Uhle boxes and suction press rolls. The press felts return in their travel loop back to the nip, to continually receive and transport water away from the web. Consequently, the press felts become contaminated with various types of soils resulting from the web compounds, and from the process shower waters used to flush the felts. Additionally, available chlorine is used in the treatment of paper machine press shower waters, which are used for felt washing and conditioning, in order to prevent microbial growths that result in slime formation that subsequently causes plugging of the shower nozzles. The residual chlorine, however, is detrimental to the nylon press fabrics. Over-treatment, or long-term accumulative effects of available chlorine can cause attack of the polyamide to the point where felt fiber shedding occurs, and press felt integrity is lost. Not only does this cause premature wear, and shorten the useful life of the press felt, but the fractured nylon fibers that become loosened from the felts contaminate the paper.
Additionally, if the paper is surface treated in the manufacturing process, i.e., on-machine coated or sized, these surface treatment systems become contaminated with the nylon-felt fibers, by transference. Sheet defects can become predominant, as manifested in “blade scratches”, when felt fibers are “snagged” by a blade coater.
Prior felt washing methods, used during the papermaking process, have relied upon dedicated chemical showers. There are four basic types of felt showers. Flooding showers are low pressure, high volume showers that flush loose particles and maintain the evenness of the water distribution in the felt. These are most effective at removing contaminants when used in conjunction with the nip of an inside felt carrying roll and require adequate vacuum to remove water volume. Flooding showers are used in tissue applications and on bleed-thru prone fine paper pickup felts.
Lubricating showers are low pressure, low volume shower used to apply a thin lubricating film of water to the felt prior to contact with a suction box to reduce wear and friction and act as a seal for the suction box. These showers apply a fan spray into the nip of the suction box with an overlapping coverage.
Chemical showers are low pressure, lower volume showers used to apply chemicals to the felt. These are most effective at removing contaminants when used in conjunction with the nip of an inside felt carrying roll. For maximum efficiency/dwell time, this shower should be placed as close to the sheet felt split and as far from the suction box as possible.
High Pressure showers are low volume showers used to physically dislodge contaminants from the felt. These are most efficient when placed close to a supporting roll.
High pressure cleaning of felts is best accomplished with an oscillating needle jet at controlled pressures. Proper oscillation of the high-pressure shower to assure uniform felt coverage is essential to an efficient felt conditioning system. Improper shower oscillation can result in a streaky felt appearance. Some sections of the felt do not receive showering and become filled while other sections of the felt receive partial or uniform showering.
All modern paper machine press sections are equipped with high pressure oscillating needle showers, just prior to the Uhle or vacuum box, as standard equipment from the machine manufacturer. These showers are provided as a means of mechanical cleaning, in order to both “chisel” away surface deposits and to loosen soils deep within the press felts void volume or base cloth. As an example, the oscillating needle showers may operate at pressures typically in the range of 150-250 psi, equipped with 0.040″ orifice spray nozzles, which are space 3″-6″ apart. These showers are designed to oscillate so as to allow the needle jets to cover the entire cross-machine direction of the press felt. The oscillation speed should ideally be matched to the rotation frequency of the press felt, so as to cover a cross-machine directional distance equal to the nozzle jet diameter, i.e., 0.040″, within the time of one nip rotation of the fabric (typically 2-4 seconds). Additionally, the shower oscillation stroke distance is often twice the needle-jet shower spacing, in order to obtain double full spray coverage of the felt. This is to compensate for a possible spray void area, should a nozzle become plugged.
Although chemicals have been applied to felts using high pressure showers at low part per million concentrations, these chemicals were limited to “conditioners” or preventative soil agents applied on a continuous basis. The high operating pressure of the needle poses difficulty in achieving sufficient cleaner concentrations to achieve adequate soil removal, so as to restore felt void-volume sufficiently, to improve felt permeability and water transport in a short period of time, such as 10-60 minutes per cleaning application. Applying sufficient cleaning composition to the felt on a continuous bases is cost prohibitive.
Further cleaning press fabrics “on-the-run”, while manufacturing paper, by injecting a detergent cleaner into the intrinsic high-pressure oscillating needle showers of a press felt, so as to remove papermaking soils for maintaining adequate press fabric de-watering, must be accomplished without adding water to the press, without disrupting the papermaking process (sheet breaks), and without causing off-quality product or sheet defects. Thus, high pressure showers have not been used for remedial or restorative chemical cleaning of press felt.
SUMMARY
The present invention encompasses application of the cleaning agent to the high pressure oscillating needle showers on a pulsed basis, with sufficient cleaning duration so as to apply full detergent coverage across the entire press fabric. The addition of cleaning agent is then discontinued for a period of time and then repeated. The cleaning agent(s) may be applied in proportion to press fabric mass, among the various press felt position on a given machine, so as to cost-optimize a press felt cleaning program.
Moreover, although applied wash time is an important parameter to consider for any on-the-run washing method, not only in light of reaction time of the cleaning chemistry upon different soil types at a given concentration, it is preferable that the wash duration will be at least equal to the period of time required to achieve full coverage of the needle jets' oscillation, as described earlier. The minimum duration of a single wash period is a function the felt rotation speed, versus the oscillation speed of the high-pressure needle shower. Preferably, the wash period should last long enough to achieve “double full coverage” by the needle jets. The wash period can be any multiple of the full coverage period.
Moreover, the washing event can be repeated multiple times over the course of a day, everyday, as needed, in order to remove soils and optimize upon the fabrics de-watering capability. Hence, use of a timer, or preferably a PLC can be used for multiple, daily wash events to optimize the press felt cleaning program.
Preferably, more than one chemical cleaning agent is administered, during a cleaning cycle or during alternate cleaning cycles. For example one can alternate between an alkaline and acidic detergent, in order to optimize cleaning efficacy for a variety of soil types.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of a press felt run partially broken away.
FIG. 2 is a diagrammatic depiction of the system used to feed cleaning agents to an oscillating needle shower.
DETAILED DESCRIPTION
FIG. 1 shows an exemplary view of a portion of a run of a papermaking felt. In this embodiment, the felt 10 runs in the direction of arrows 12 over various rollers (not shown). A high pressure oscillating needle shower 14 applies chemical to felt 10 immediately upstream of double UHLE box 16 . The particular location of the high pressure shower is a matter of choice. Further, various low pressure showers are typically used to treat the felt 10 . The selection and location of these is determined by the particular application, and forms no portion of the present invention.
Further, as shown in FIG. 2 , a chemical feed system 40 includes apparatus to introduce one or more cleaning fluids into the high pressure flow of liquid to the oscillating shower 14 . As shown in FIG. 2 , there are two cleaning chemical reservoirs 42 and 44 both with pumps 46 and 48 used to draw cleaning solution from reservoirs 42 and 44 and direct these upstream of a high pressure pump 50 which directs liquid, generally water, from a reservoir 51 or other source to the needle shower 14 . Pumps 46 and 48 are controlled by a PLC 52 which controls the amount of chemical pumped as well as the timing of the introduction of the chemicals, as discussed below.
Although FIG. 2 shows two chemical reservoirs 42 and 44 , it is possible to have only one chemical reservoir with one pump, or, alternately, three or more selected chemicals. However, the selection of two chemicals, as discussed below, is preferred.
According to the present invention, a cleaning chemical is forced through the high pressure needle nozzles 14 as paper is being manufactured. However, the chemicals are introduced on an intermittent basis.
As discussed above, the needle showers produce a very small, approximately 0.04 inch diameter, spray of water at a very high pressure, generally 150 to 250 psi, directly against the felt. Typically, the oscillating needle showers include a series of the needle nozzles spaced 3 inches to 6 inches apart, each with a 0.04 inch spray diameter. Thus, at any one time, the needle shower contacts only a small portion of the felt. Therefore, the nozzles are oscillated back and forth as the felt moves. Over a period of time, which depends upon the speed of the felt and the speed of the oscillation, the entire felt will be uniformly contacted with the spray from the needle showers. This period of time is referred to hereinafter as the full coverage period.
The needle showers themselves are operated continuously during the entire period of time that paper is being manufactured. Therefore, any time that the felt is moving, the needle showers should be applying the high pressure spray of material against the felt, and should be oscillating back and forth to ensure full coverage.
A cleaning solution is added intermittently through the needle showers as paper is being manufactured. The cleaning solution must be injected through the nozzles for a period of time at least equal to the full coverage period, and, preferably, for twice the full coverage period. This ensures that the entire felt is contacted with the cleaning solution. Subsequent to this period of time, the addition of the cleaning solution through the needle shower is discontinued. However, the papermaking process and the application of water without cleaning solution through the needle nozzle continues.
The actual duration of the full coverage period depends upon the felt rotation speed so as to achieve full coverage with the oscillating needle shower (the stroke timed to speed matching of the felt rpm per 0.040 inches movement). For a four felted machine at higher operating speeds, i.e., 3000-3600 fpm, the cleaning solution feed is on for about 15 minutes maximum each hour. This provides for double full coverage.
For a three-felted machine at the same speed, 20 minutes per hour is sufficient. For slower speeds, i.e., 2200-2800 fpm, 24 minutes of treatment each hour is optimal. Generally, the minimum off time between cleaning applications will be at least one full coverage period. The inactive time, i.e., the period of time between cleaning times, should be no longer than 50 minutes. If the period of time between cleaning is too long, too much soil will fill the felt. Applying the cleaning chemical operation at least once per hour causes a cumulative effect on the felt providing significant cleaning for the felt.
The cleaning solution used in the present invention can be any cleaning solution typically employed to clean papermaking felt. Depending upon the chemistry of the particular equipment, these cleaning compositions can be alkaline, acid, anionic, or nonionic. Therefore, one will select one or more cleaning compositions, based on the particular papermaking operation. Generally, they will include, in addition to surfactants and the requisite acid or base wetting agents, chelants and sequestrants. Exemplary formulations for both acid and alkaline cleaning compositions are set out below (parts by weight).
Alkaline felt wash
water
63.4-73.4
potassium hydroxide
15.0-20.0
complex phosphate
5.0-15.0
surfactant amphoteric
0.1-0.75
chelant
2.0-5.0
sequestrant
0.2-1.0
Acidic felt wash
water
66.0-78.0
organic acid (acetic)
10.0-20.0
phosphoric acid sequestrant
5.0-15.0
surfactant amphoteric
1.0-4.0
glycol ether solvent
2.0-8.0
chlorine scavenger
0.05-0.25
The chemical compositions are generally added at about 200 to 600 ppm on a 100% actives basis. The detergent compositions themselves, however, are generally diluted and contain about 15-20% actives.
Since the total amount of soil which is deposited within a press fabric is basically proportional to the felt area, and since all press fabrics on a given machine are the same width (differing by their length), then the amount of press felt cleaner for each press felt can optimally be applied in proportion to the fabric's length, to achieve the same degree of cleanliness. It is best to adjust the concentration of the detergent applied to each felt based upon relative length and soil loading, rather than adjusting detergent feed duration. If the detergent feed duration were varied proportionally in the following example, the coverage of the oscillating needed shower coverage would not result in uniform application of the cleaner. For instance, for a given tri-nip press on a fine paper machine, the Pickup, first bottom press, and third top press felts all have a width of 320″, and the following lengths respectively: 76′, 55.5′ and 46 feet. Thus, in proportion to their area, the press felts would be allocated approximately: 43%, 31% and 26% respectively, of the daily detergent allotment.
In a preferred embodiment, two different cleaning agents are applied alternately with spaced time intervals between the applications. As shown in FIG. 2 , in a preferred embodiment the two different cleaning agents, one alkaline the other acid, or, alternately, one anionic and one nonionic, or one alkaline or acid and the second one neutral, are applied by apparatus 40 shown in FIG. 2 . In this embodiment, the two different chemicals are stored in reservoirs 42 and 44 controlled by pumps 46 and 48 , which, in turn, are controlled by a PLC 52 . Pumps 46 and 48 inject the chemical into the inlet line 60 between the pump 50 and the needle shower 32 . In a preferred embodiment, one of the cleaning solutions is applied for a period of time, preferably equal to twice the full coverage period. The PLC will discontinue the flow of the cleaning solution for a period of time, generally for the remaining portion of the hour. Next, the PLC will inject the second cleaning solution through the needle shower 14 , preferably for twice the full coverage period. The PLC will then discontinue application of cleaning solution for a period of time. This will be repeated continuously while the papermaking machine is producing paper.
The invention will be further appreciated in light of the following example.
EXAMPLE
Improved Paper Machine Sheet Quality, Runability, and Yield
A test was performed on a fine paper machine equipped with a Twin-ver press, plus straight-through third press and smoothing press, which produced light and medium basis weight free sheet paper grades. Previously, this machine had attempted to enact soils prevention by use of a cleaner continuously, through the high-pressure showers, with insufficient results. As a result, downtime cleaning of the press fabrics (no paper being manufactured on the reel) was required with an alkaline detergent. This not only caused loss of paper production, but also led to culled production during manufacturing, due to sheet defects that occurred in between the intervals of downtime washing events. These defects, i.e., corrugations, wrinkles, and ridges were caused by variation in cross-direction (CD) moisture content of the sheet. This was caused by soiling of the press felts, and due to the fact that no “on-the-run” felt washing capability was available to correct the problem. Additionally, no machine moisture adjustments were available other than dry weight headbox control.
The test consisted of application of alternating two cleaning compounds through the high pressure showers of each press fabric at various frequencies and durations, and measuring the effects upon felt Uhle box vacuums, press filtrate de-watering rates, press felt water permeability profiles, press felt service life, sheet quality, and machine runnability and up-time. The best results were observed when an acid and alkaline cleaner were alternated every other hour, at the rate of 24 minutes on and 36 minutes off, each hour (12 feed cycles each, per day), at a concentration in the range of 0.12-0.15%. This novel cleaning program resulted in huge improvements to the paper machine's production and quality yield, buy lowering CD sheet moisture variation (improvement in reel-shape, and fewer sheet breaks during felt washing). The overall results of the new cleaning program were as follows:
The trial machine monthly total losses for wrinkles were reduced to 19.1 Tons during the 4-month trial period, from 58.2 Tons (pre-trial) and a monthly average of 54.3 tons. Annualized this would result in a reduction of cull loss for wrinkles of 469.2 Tons.
The trial machine monthly total losses for ridges was reduced to 7.8 Tons during the 4 month trial period, from 71.1 Tons (Pre-trial) and a monthly average of 34.8 tons. Annualized this would result in a reduction of cull losses for ridges of 759.6 Tons.
The trial machine monthly total losses for corrugations was reduced to 41.5 Tons during the 4-month trial period, from 65.6 Tons (Pre-trial) and a monthly average of 38.8 tons. Annualized this would result in a reduction in culls for corrugations of 289.2 Tons.
The sum total of estimated reductions in annual culls for ridges, wrinkles and corrugations is 1,518 Tons for this trial machine.
Total cull losses for ridges, wrinkles, and corrugations on the trial machine's winder and super calendar were substantially lower in almost every category, during the trial period.
The present invention, when compared to standard cleaning methods, provided significant improvement in water permeability of the press fabric over its entire service life. There was, further, a significant reduction in the vacuum as measured at the UHLE box.
Further, alternating alkaline and acidic cleaners utilizing the method of the present invention further provided significantly improved results versus using only alkaline or only acidic cleaners. Hence, alternating cleaning chemistry types can increase felt void volume and improve felt dewatering performance over the useful life of the felt.
Further, due to the fact that the present invention uses relatively low concentration of cleaning solution, generally around 0.2 percent, whereas a standard cleaner might be used at a much higher rate, such as 3 percent, has relatively no impact on paper quality. Thus, the cleaning can be conducted while paper is being manufactured without causing sheet defects or sheet breaks. Further, since a relatively small amount of cleaning is applied, there is minimal impact on the cost of the paper. Further, the cost in chemicals is significantly less than the expense occurred in down time required to clean the felt off line.
This has been a description of the present invention along with the preferred method of practicing the invention. However, the invention itself should only be defined by the appended claims.
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An apparatus is described for cleaning papermaking felt by applying a low concentration of a cleaning solution through the oscillating needle nozzles. The detergent is applied intermittently while paper is being manufactured. Each cleaning period lasts for at least the length of time required for the nozzles to cover the entire surface of the felt, and preferably twice that period of time. The application of cleaning solution is then discontinued for a period of time. This cycle is repeated continuously as the paper is being manufactured. The apparatus includes a first cleaning chemical reservoir, a second cleaning chemical reservoir, a high pressure pump coupled to the first and second reservoirs, and a control unit having programming for selectively injecting the chemicals.
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BACKGROUND OF THE INVENTION
The present invention relates to a soluble form of intercellular adhesion molecule (sICAM-1) as well as the DNA sequence encoding sICAM-1. sICAM-1 and ICAM-1 have substantial similarity, in that they share the first 442 NH 2 -terminal amino acids of the extracellular domain. However, sICAM-1 differs from ICAM-1 at the C-terminus, and these changes confer solubility to sICAM-1. ICAM-1 is known to mediate adhesion of many cell types, including endothelial cells, to lymphocytes which express lymphocyte function-associated antigen-1 (LFA-1). ICAM-1 has the property of directly binding LFA-1. There is also evidence for LFA-1 mediated adhesion which is not via ICAM-1. Additionally, ICAM-1 has the ability to bind both LFA-1 and human rhinovirus. It has the property of inhibiting infection of rhinovirus and Coxsackie A viruses. It may be used to antagonize adhesion of cells mediated by ICAM-1 binding including ICAM-1/LFA-1 binding and thus be useful in treatment of inflammation, graft rejection, LFA-1 expressing tumors, and other processes involving cell adhesion. Based on the substantial similarity of the extracellular domains of ICAM-1 and sICAM-1, sICAM-1 has the properties identified for ICAM-1.
The major Human Rhinovirus Receptor (HRR) has been transfected, identified, purified and reconstituted as described in co-pending U.S. patent applications Ser. Nos. 262570 and 262428 filed Oct. 25, 1988. This receptor has been shown to be identical to a previously described cell surface protein, ICAM-1. European Patent Application 0 289 949 describes a membrane associated cell adhesion molecule (ICAM-1) which mediates attachment of many cell types including endothelial cells to lymphocytes which contain LFA-1. This patent application provides a discussion of the present research in the field of intercellular adhesion molecules. It is important to note that the inventors specifically looked for an alternatively spliced mRNA for ICAM-1 and did not identify one. ICAM-1 was first identified based on its role in adhesion of leukocytes to T-cells (Rothlein, R. et a, J. Immunol. 137:1270-1274(1986)) which has been shown to be mediated by the heterotypic binding of ICAM-1 to LFA-1 (Marlin et al, Cell 51:813-819(1987)). The primary structure of ICAM-1 has revealed that it is homologous to the cellular adhesion molecules Neural Cell Adhesion Molecule (NCAM) and Mylein-Associated Glycoprotein (MAG), and has led to the proposal that it is a member of the immunoglobulin supergene family (Simmons et al, Nature 331:624-627 (1988); Staunton et al, Cell 52:925-933(1988)). The DNA sequence of cDNA clones are described in the above referenced papers by Simmons et al and Staunton et al, supra, from which the amino acid sequence of ICAM-1 can be deduced. The ICAM-1 molecule has a typical hydrophobic membrane spanning region containing 24 amino acids and a short cytoplasmic tail containing 28 amino acids. The ICAM-1 of the prior art is an insoluble molecule which is solubilized from cell membranes by lysing the cells in a non-ionic detergent. The solubilized ICAM-1 mixture in detergent is then passed through a column matrix material and then through a monoclonal antibody column matrix for purification.
SUMMARY OF THE INVENTION
The present invention provides an endogenous alternatively spliced molecular species of ICAM-1 designated sICAM-1 which displays an alternative mRNA sequence and which is soluble without the addition of a detergent.
The present invention provides purified and isolated human soluble intercellular adhesion molecule (sICAM-1), or a functional derivative thereof, substantially free of natural contaminants. sICAM-1 can be obtained from HeLa,HE1 and primary transfectant cells thereof characterized by being soluble in the absence of nonionic detergents and being the translation product defined by a novel mRNA sequence. This natural product of human cells has the advantage of being secreted from cells in a soluble form and not being immunogenic. The natural soluble product differs from the natural insoluble product in that the soluble product contains a novel sequence of 11 amino acid residues at the C-terminus and does not contain the membrane spanning and cytoplasmic domains present in the insoluble form.
The present invention provides a purified and isolated DNA sequence encoding sICAM-1 as well as a host cell encoding said sequence.
The present invention provides a method of recovering soluble intercellular adhesion molecule in substantially pure form comprising the steps of:
(A) removing the supernatant from unlysed cells,
(B) introducing the supernatant to an affinity matrix containing immobilized antibody capable of binding to sICAM-1,
(C) permitting said sICAM-1 to bind to said antibody of said matrix,
(D) washing said matrix to remove unbound contaminants, and
(E) recovering said sICAM-1 in substantially pure form by eluting said sICAM-1 from said matrix.
Further purification utilizing a lectin or wheat germ agglutinin column may be used before or after the antibody matrix step. Other purification steps could include sizing chromotography, ion chromotography, and gel electrophoresis. Further purification by velocity sedimentation through sucrose gradients may be used. The antibody capable of binding to sICAM-1 could include antibodies against ICAM-1 or HRR.
The present invention includes polyclonal antibodies against sICAM-1.
The present invention further includes an antibody specific for sICAM-1, capable of binding to the sICAM-1 molecule and that is not capable of binding to ICAM-1. For a method for producing a peptide antisera see Green et al, Cell 28:477-487 (1982). The invention also includes a hybridoma cell line capable of producing such an antibody.
This invention further includes the therapeutic use of antibodies specifically directed to sICAM-1 to increase the adhesion of cells mediated by ICAM-1 and LFA-1.
The invention further includes a method for producing an antibody which is capable of binding to sICAM-1 and not to ICAM-1 comprising the steps of
(A) preparing a peptide-protein conjugate said peptide-protein conjugate specific to at least a portion of the unique 11 amino acid sequence present in sICAM-1,
(B) immunizing an animal with said peptide-protein conjugate,
(C) boosting the animals, and
(D) obtaining the antisera.
The antibodies would be capable of binding to sICAM-1 and not capable of binding to ICAM-1.
The invention includes the hybridoma cell line which produces an antibody of the same specificity, the antibody produced by the hybridoma cell and the method of production.
The invention further includes a method of inhibiting lymphocyte function associated antigen (LFA-1) and intercellular adhesion molecule-1 (ICAM-1) interaction comprising the step of contacting LFA-1 containing cells with sICAM-1 or a functional derivative thereof. This method of inhibition of ICAM-1 adhesion has application in such disease states as inflammation, graft rejection, and for LFA-1 expressing tumor cells.
This invention further includes a method of diagnosis of the presence and location of an LFA-1 expressing tumor cell.
This invention further includes a method for substantially reducing the infection of human rhinoviruses of the major receptor group comprising the step of contacting the virus with sICAM-1 or a functional derivative thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1, parts A and B show the nucleotide and amino acid sequence of sICAM-1.
FIG. 2 is a comparison of the C-terminal regions of sICAM-1 and ICAM-1. The nucleotide and deduced amino acid sequences of ICAM-1 and sICAM-1 are shown beginning at amino acid residue 435. Dashes in the sICAM-1 sequence indicate missing nucleotides. The positions of the stop codons in both proteins are indicted by an asterick.
FIGS. 3A and B are comparisons of the structure of sICAM-1 and ICAM-1. The membrane spanning region of ICAM-1 is indicated by the stippled box and the cytoplasmic domain by the hatched box. The novel C-terminus of sICAM-1 is indicated by the solid box. The five predicted domains showing homology with immunoglobulin are numbered I to V.
FIGS. 4A, B, and C show the ICAM-1 gene and its expression in HRR transfectants. FIG. 4A: Southern blot of HeLa (Lane 1) LTK- (Lane 2) and HE1 (Lane 3) DNA restricted with Eco, R1 and probed with the oligonucleotide ICAM-1; FIG. 4B: Northern blot of HeLa (Lane 1), Lkt - (Lane 2),and HE1 (lane 3). poly A+ RNA probed with the oligonucleotide ICAM-1;
FIG. 4C: PCR amplification of cDNA prepared from HeLa (Lane 1), Ltk - (Lane 2) and HE1 (Lane 3) poly A+ RNA. The primers used were from the N-terminal and C-terminal coding regions of ICAM-1 having the sequence ggaattcATGGCTCCCAGCAGCCCCCGGCCC and ggaattcTCAGGGAGGCGTGGCTTGTGTGTT. Upper case denotes ICAM-1 sequence, lower case restriction site linkers. Lanes 1 and 2, 72 hour exposure, Lane 3, 90 minute exposure.
FIG. 5 is a gel showing the detection of the ICAM-1 and sICAM-1 mRNAs in HeLA and HE1 cells. PCR amplification was performed on 100 ng single stranded cDNA using the primers PCR 5.4 (CTTGAGGGCACCTACCTCTGTCGG) and PCR 3.4 (AGTGATGATGACAATCTCATACCG). Extensions were performed at 72 C. for 25 cycles and one tenth of the product was analysed on a 1% agarose/3% NuSieve gel. Lane 1, HeLa cDNA; lane 2, HE1 cDNA; lane 3, LTK- cDNA; lane 4, ICAM-1 phage control;, lane 5, sICAM-1 phage control; lane 6, ICAM-1+sICAM-1 phage control. Specific amplification products of 105 bp and 86 bp are indicated by the arrows.
FIG. 6 is a Western blot showing the synthesis of a soluble form of ICAM-1 protein by HeLa and HE1 cells. It demonstrates the existence of a protein species in the culture supernatant of HE1 cells related to ICAM-1. Equivalent aliquots of cell lysates and culture supernatants were separated by SDS-PAGE, blotted onto nitrocellulose, and probed with a rabbit polyclonal antisera to ICAM-1 followed by 125 I protein A; a species migrating close to the position of membrane-bound ICAM-1 is seen in HE1 culture supernatants.
FIG. 7 is a graphical representation of the cloned sICAM-1 and ICAM-1 plasmids.
FIG. 7, part "A" indicated nucleic acid sequences encoding portions of the sICAM-1 molecule. pHRR3 is a full length cDNA encoding sICAM-1 obtained by PCR. Clones 19.1-3 and 4.5 are partial cDNA clones encoding sICAM-1 obtained from an HE1 cDNA library in lambda GT11. Beneath the clones is a schematic of the sICAM-1 molecule. S denotes the signal peptide and I to V the IgG homologous domains. The solid box indicates the unique 11 amino acid C-terminus
FIG. 7, part "B" indicates nucleic acid sequences encoding portions of the ICAM-1 molecule. pHRR1 and pHRR2 are full length ICAM-1 cDNA clones obtained by PCR. The remaining ICAM-1 clones were obtained from an HE1 cDNA library in lambda GT11. Beneath the clones is a schematic of the ICAM-1 molecule, showing the signal peptide (S), the five IgG homologous domains (I to V), the transmembrane region (TM) and the cytoplasmic domain (C).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
One aspect of the present invention relates to the discovery of a soluble natural binding ligand to the receptor binding site of Human Rhinovirus (HRV) and which also binds to LFA-1. This soluble natural molecule is related to but distinct from the molecule designated "Intercellular Adhesion Molecule-1" or "ICAM-1" which is insoluble, bound to the cell membrane and possesses a typical hydrophobic membrane spanning region and a short cytoplasmic tail. The novel protein of the present invention has a DNA sequence which includes a significant difference from the published DNA sequence for ICAM-1. sICAM-1 contains most of the extracellular domain of ICAM-1, which includes the functional domains for multiple functions including HRV and LFA-1 binding, but lacks the membrane spanning and cytoplasmic domains. sICAM-1 retains the ability to bind HRV and LFA-1 and is secreted in a soluble form. The DNA sequence for sICAM-1 contains a deletion of 19 base pairs from nucleotide 1465 to 1483 according to the numbering of Staunton et al, supra (1988). The remainder of the sICAM-1 clone matches the published ICAM-1 sequence with the exception of a substitution of a G for A at nucleotide position 1462 which changes Glu 442 to Lys, as shown in FIG. 1. The sequence of amino acid residues in a peptide is designated in accordance with standard nomenclature such as Lehninger's Biochemistry, Worth Publishers, New York, N.Y. (1970). sICAM-1 is a natural product of HeLa and HE1 cells and other human cells which should have the property of binding to and inhibiting the infection of human rhinovirus and Coxsackie A viruses. It also has the property of binding to LFA-1 and may be used to antagonize adhesion of cells mediated by ICAM-1/LFA-1 binding and thus be useful as a therapeutic in treatment of inflammation, graft rejection, suppression of LFA-1 expressing tumor cells and other processes involving cell adhesion. Isolated and purified sICAM-1 protein as a therapeutic would not possess the immunogenic problems associated with foreign proteins. The secretion of a soluble naturally occurring protein eliminates the problems associated with production and purification of an insoluble, cell membrane bound protein, since cell lysis is not required and thus continuous culture can be employed as well as simplified procedures for purification and isolation of sICAM-1.
Non-human mammalian cell lines which express the major human rhinovirus receptor gene have been previously identified and are the subject matter of copending U.S. patent application Ser. Nos. 262570 and 262428 filed Oct. 25, 1988, and include references to the ATCC deposits for the cell lines. High-expressing cell line HE1 was deposited with the ATCC on Nov. 19, 1987 under accession no CRL 9592. The major human rhinovirus receptor was identified with monoclonal antibodies which inhibit rhinovirus infection. These monoclonal antibodies recognized a 95 kd cell surface glycoprotein on human cells and on mouse transfectants expressing a rhinovirus-binding phenotype. Purified 95 Kd protein binds to rhinovirus in vitro. Protein sequence from the 95 kd protein showed an identity with that of ICAM-1; a cDNA clone obtained from mouse transfectants expressing the rhinovirus receptor had the same sequence published for ICAM-1, except for the G for A change previously described. Thus it was determined that the major human rhinovirus receptor and ICAM-1 were the same protein. A transfected mouse L-cell line designated HE1 had been been isolated which contained and expressed the HRR gene or ICAM-1 gene. The ICAM-1 terminology has been used although it is now recognized that HRR and ICAM-1 are interchangeable.
A randomly primed cDNA library was prepared in lambda GT11 from HE1 polyA+ RNA. The library was screened in duplicate using two oligonucleotides derived from the published sequence of ICAM-1. Oligonucleotide ICAM-1 has the sequence GAGGTGTTCTCAAACAGCTCCAGCCCTTGGGGCCGCAGGTCCAGTTC and oligonucleotide ICAM-3 has the sequence CGTTGGCAGGACAAAGGTCTGGAGCTGGTAGGGGGCCGAGGTGTTCT.
Eight positive clones were obtained from one screen and three were selected for further study. DNA sequencing of two of the clones showed identity with the published ICAM-1 sequence. The sequence of the third clone, lambda 19.1-3 was significantly different from the other two clones in that there was a deletion of 19 bp from nucleotide 1465 to 1483 according to the numbering of Staunton et al, supra. The 19 bp deletion was present in a second cDNA, lambda HE1-4.5 and independently confirmed using polymerase chain reaction (PCR) generated cDNA. Analysis of the cDNA sequence predicted the existence of a secreted form of ICAM-1 that is generated by an alternative splicing mechanism. Western blot identification of sICAM-1 from culture supernatants of HE1 and HeLa cell lines confirm that the sICAM-1 mRNA sequence encodes a soluble form of ICAM-1 that does not associate with the cell surface but is released into the cell medium. An alternatively spliced mRNA generating a secreted form of another adhesion molecule (NCAM) has been identified (Glower et al, Cell 5:955-964 (1988)), although in NCAM an exon is incorporated into the mRNA while in the present invention an exon is delted from the mRNA. No alternative mRNA sequence for ICAM-1 had previously been identified.(Staunton et al.).
sICAM-1 cDNA Clones
A randomly primed cDNA library was constructed in lambda GT11 from HE1 poly A+ by Clontech Laboratories, Palo Alto, Calif. The library was screened with two 47 mer oligonucleotide probes from the middle of the ICAM-1 coding sequence. A positive clone designated 19.1-3 was isolated which had an insert of 1.5 kb; a second cDNA clone designated 4.5 which has an insert of 1.25 kb was isolated; and an additional cDNA clone pHRR-3 was obtained by subcloning the products of PCR amplification into Bluescript utilizing the Perkin-Elmer/Cetus DNA Amplification System, Perkin Elmer, Wellesley Mass., as shown in FIG. 4C, lane 3. These clones showed a significant difference from the published ICAM-1 sequence. They all contain a deletion of 19 base pairs from nucleotide 1465 to 1483 according to the numbering of Staunton et al, supra. In order to demonstrate directly that the s-ICAM mRNA is present in HE1 cells and HeLa cells, a PCR experiment was performed using primers which flank the 19 bp region which is absent from the s-ICAM mRNA (FIG. 8). Using these primers the product from the ICAM-1 mRNA is 105 bp while the s-ICAM-1 product is 19 bp shorter i.e. 86 bp. This experiment shows that both HE1 cells and HeLa cells contain both forms of the ICAM-1 mRNA while the control L-cells do not. A synthetic oligonucleotide designated PCR3.2 having the following sequence:
ggaattcTCACTCATACCGGGGGGAGAGCACATT
was used to distinguish between cDNA clones containing the 19 bp deletion from clones not containing the 19 bp deletion. The synthetic oligonucleotide does not bind to cDNA clones which contain the 19 bp deletion. In addition, partial sequence of the cDNA 19.1-3 and PHRR-3 confirmed the 19 bp deletion. This data indicates that there are at least two different and distinct ICAM-1 species in HE1 cells. The insoluble ICAM-1 of the prior art and a novel soluble form as described in the present invention.
The sequences of the deleted (sICAM-1) and the nondeleted (ICAM-1) forms of the Intercellular Adhesion Molecule-1 mRNA represented by the cDNA clones are shown in FIG. 2. The sequence at the point of deletion is AGGT consistent with an RNA splice junction. The removal of 19 bases from the mRNA shifts the reading frame and causes the two polypeptide sequences to diverge at amino acid residue 443. The deleted form (sICAM-1)contains an additional 11 residues followed by an in-frame termination codon. This molecule thus consists of 453 amino acids as compared to 505 amino acids for the nondeleted form. Beginning with the N-terminus of ICAM-1, sICAM-1 has 442 amino acids in common with ICAM-1. The deleted form (sICAM-1) contains a unique 11 amino acid C-terminus but lacks the membrane spanning (24 amino acids) and cytoplasmic tail (28 amino acids) domains of ICAM-1, as shown in FIG. 3.
ICAM-1 cDNA Clones
A plurality of methods may be used to clone genes. One method is to use two partially overlapping 47mer oligonucleotide probes. These two probes termed oligonucleotide ICAM-1 and oligonucleotide ICAM-3 were synthesized from the published ICAM-1 sequence. The ICAM-1 oligonucleotide was labeled to high specific activity and hybridized to a Southern blot under high stringency conditions. As shown in FIG. 4A, a single band of 4.4 kb was detected in HeLa, HE1 and two primary HRR transfectant cell lines and was absent from Ltk - cells. This result confirms that the HRR transfectants contain the human ICAM-1 gene. The size of the fragment agrees with Simmons et al but differs from Staunton et al probably reflecting a restriction site polymorphism.
The ICAM-1 oligonucleotide was used to probe a Northern blot of poly A+ RNA from the same cell lines. As shown in FIG. 4B, an mRNA of 3.3 kb was detected in HeLa, HE1, and primary transfectant cell lines but was absent from Ltk - cells. The signal in HE1 cells was many times stronger than the other cell lines indicating a much higher level of mRNA in HE1 cells. This is in agreement with the higher level of HRR (ICAM-1) expression in HE1 cells. A second 2.4 kb RNA was also detected in HE1 cells. These data confirm that the human ICAM-1 mRNA is expressed in HRR transfectants. See FIG. 4B.
The human ICAM-1 gene was isolated from the HE1 transfectant using polymerase chain reaction (PCR) amplification utilizing the Perkin-Elmer/Seats DNA Amplification System, Perkin Elmer, Wellesley Mass. PCR amplification was performed on single stranded cDNA made from HeLa, Ltk - and HE1 RNA. Primers were made from the 5' and 3' coding regions of the published ICAM-1 sequence. ICAM-1 specific amplification products were detected by hybridization of a Southern blot of the PCR reactions using the ICAM-1 oligonucleotide. As shown in FIG. 4C, a single band of approximately 1600 bp which matches the predicted size was amplified from HeLa cells and HE1 cells but was absent from Ltk - cells. The amplification product was cloned into Bluescript (Stratagene, San Diego, Calif.) and two independent clones designated PHRR1 and PHRR2 were obtained. The complete sequence of PHRR2 showed 100% identity with the published ICAM-1 coding sequence with the exception of the single G to A change previously described.
A lambda GT11 library made from randomly primed HE1 cDNA was screened with the ICAM-1 and ICAM-3 probes and eight positive clones were isolated. Six clones as shown in FIG. 7 were selected for further study and were analyzed by partial DNA sequencing. A total of approximately 1000 nucleotides of sequence derived from these clones showed identity with the ICAM-1 sequence.
Purification and Isolation of Soluble protein
HeLa and HE1 cells are grown under standard conditions in DMEM (Dulbecco's Modified Essential Media) with 10% Fetal Bovine Serum. Conditioned media from these cells is harvested and centrifuged or filtered to remove cells or cellular debris. The cell-membrane bound ICAM-1 is not present in the supernatant. This media is then absorbed to a monoclonal antibody-sepharose resin (the monoclonal antibody c78.4A being an example) in which the monoclonal antibody is directed to ICAM-1 or sICAM-1 and the unabsorbed proteins are washed from the resin with a physiological saline buffer, such as phosphate-buffered saline. The bound sICAM-1 is then eluted under conditions that preserve the native conformation of the protein, as described in copending application Ser. No. 262428 filed Oct. 25, 1988. Denaturation of the receptor can be determined by monitoring the ability of the extracted protein to inhibit virus infectivity or by sensitivity to proteolysis. It has been determined that the receptor can be denatured by heating at 60° C. for 30 minutes or by treatment with 1% SDS indicating that care need be taken to maintain the native conformation of the HRV binding site. Appropriate conditions for dissociating receptor complexes from the antibody can be determined empirically and can be expected to vary somewhat from antibody to antibody. Dissociation by raising pH has been found in some cases to be most effective with low pH or high salt conditions being operable but producing lower protein yields. Elution under nondenaturing conditions can be achieved with a high pH buffer (0.05M diethanolamine (pH 11.5)) for 1 hour at room temperature. The eluant is removed, neutralized by the addition of 0.2 volumes of 1M HEPES (pH 7.2), dialyzed against three changes of a physiological buffer (0.01M HEPES, 0.150 NaCl, 0.001M CaCl 2 , pH 7.5). The sICAM-1 may be further purified by lectin affinity chromotography, ion exchange chromatography, or gel filtration.
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The present invention relates to a soluble form of intercellular adhesion molecule (sICAM-1) and purified and isolated human sICAM-1. This invention also relates to a purified and isolated DNA sequence encoding sICAM-1. The extracellular domain of sICAM-1 and insoluble ICAM-1 are substantially the same. ICAM-1 is involved in the process through which lymphocytes attach to cellular substrates during inflammation and serves as the major human rhinovirus receptor (HRR). sICAM-1 therefore has both the property of reducing immune inflammation and inhibiting infection of rhinovirus and Coxsackie A virus.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/243,080, filed Oct. 25, 2000, entitled PARALLEL PLATE DEVELOPMENT WITH THE APPLICATION OF A DIFFERENTIAL VOLTAGE.
TECHNICAL FIELD
[0002] The present invention generally relates to semiconductor processing, and in particular to a system and method for optimal development of a photoresist material layer on a wafer.
BACKGROUND OF THE INVENTION
[0003] In the semiconductor industry, there is a continuing trend toward higher device densities. To achieve these high densities there has been and continues to be efforts toward scaling down device dimensions (e.g., at submicron levels) on semiconductor wafers. In order to accomplish such high device packing density, smaller and smaller features sizes are required. This may include the width and spacing of interconnecting lines, spacing and diameter of contact holes, and the surface geometry such as comers and edges of various features.
[0004] The requirement of small features with close spacing between adjacent features requires high resolution photolithographic processes. In general, lithography refers to processes for pattern transfer between various media. It is a technique used for integrated circuit fabrication in which a silicon structure is coated uniformly with a radiation-sensitive film, the resist, and an exposing source (such as optical light, x-rays, or an electron beam) illuminates selected areas of the surface through an intervening master template, the mask, for a particular pattern. The lithographic coating is generally a radiation-sensitive coating suitable for receiving a projected image of the subject pattern. Once the image is projected, it is indelibly formed in the coating. The projected image may be either a negative or a positive image of the subject pattern. Exposure of the coating through a photomask causes the image area to become either more or less soluble (depending on the coating) in a particular solvent developer. The more soluble areas are removed in the developing process to leave the pattern image in the coating as less soluble polymer.
[0005] Due to the extremely fine patterns which are exposed on the photoresist material, thickness uniformity of the photoresist material is a significant factor in achieving desired critical dimensions. The photoresist material should be applied such that a uniform thickness is maintained in order to ensure uniformity and quality of the photoresist material layer. The photoresist material layer thickness typically is in the range of 0.1 to 3.0 microns. Good resist thickness control is highly desired, and typically variances in thickness should be less than ±10-20 Å across the wafer. Very slight variations in the photoresist material thickness may greatly affect the end result after the photoresist material is exposed by radiation and the exposed portions removed.
[0006] Application of the resist onto the wafer is typically accomplished by using a spin coater. The spin coater is essentially a vacuum chuck rotated by a motor. The wafer is vacuum held onto the spin chuck. Typically, a nozzle supplies a predetermined amount of resist to a center area of the wafer. The wafer is then accelerated to and rotated at a certain speed, and centrifugal forces exerted on the resist cause the resist to disperse over the whole surface of the wafer. The resist thickness obtained from a spin coating process is dependent on the viscosity of the resist material, spin speed, the temperature of the resist and temperature of the wafer.
[0007] After the resist is spin coated and selectively irradiated to define a predetermined pattern, the irradiated or nonirradiated portions are removed by applying a developer material. The developer material is also spin coated onto the wafer by applying developer material across the resist and then spin coating the developer material until centrifugal forces disperse the developer material over the coating of resist. Due to the surface of the photoresist material layer on the semiconductor being highly hydrophobic, the surface can repel the developer material at the initial state of jetting out the developer material from the developer supply nozzle so that turbulent flow of the developer material is generated on the surface of the resist forming bubbles. The bubbles produced between the photoresist material layer and the developer material are a cause of defects in the resist pattern. Additionally, due to the developer being spincoated along a central point of the photoresist, the developer is not always uniformly applied across the photoresist material. This non-uniform distribution of developer can result in semiconductor defects.
[0008] Moreover, non-uniform distribution of developer causes problems related to critical dimension (CD) control. In particular, non-uniform distribution of developer across the photoresist means that substrates (typically, wafers or masks) have locations of different CD control. One must therefore consider these differences when attempting to optimize CD control, thereby compromising CD control quality in certain areas of the substrate.
[0009] After the photoresist material layer has been developed, the irradiated or nonirradiated portions are removed by rinsing or washing with a washing solution material. Each time a photoresist material layer is to be developed, a developer nozzle moves to the center of the photoresist material layer and applies the developer material. The developer nozzle then moves to the rest position and a washing solution nozzle moves above the wafer to rinse the developed portions and the developer material off the photoresist material layer. This constant movement of the different nozzles not only takes up a great deal of time, but eventually leads to mechanical problems and increased maintenance.
[0010] A prior art developer nozzle and washing solution application system is illustrated in FIGS. 1 a - 1 b . A multiple tip developer nozzle 10 is coupled to a pivotable arm 12 that pivots from a rest position to an operating position. In the operating position, the multiple tip nozzle 10 applies a developer material 26 on a resist layer 24 disposed on a wafer 22 . The wafer 22 is vacuum held onto a rotating chuck 20 driven by a shaft 18 coupled to a motor 16 . The developer material flows outward from the center of the photoresist material layer 24 covering the entire top surface of the photoresist material layer 24 . A washing solution nozzle 28 is coupled to an arm 32 and moves from an operating position to a rest position. The washing solution nozzle provides a washing solution material 30 to rinse the developed photoresist and the developer material from the photoresist material layer 24 . As illustrated in FIG. 1 a , the washing solution nozzle 28 is typically at a much greater distance from the photoresist material layer in its operating state than the developer nozzle is when it is in its operating state resulting in a splashing effect that can scatter particles and cause defects.
[0011] In view of the above, there is an unmet need for a system/method for dispensing a uniform layer of developer across a photoresist material layer formed on a wafer. There is also and unmet need for a system/method that provides a rinse that mitigates splashback during rinsing of the developed photoresist and developer material from a photoresist material layer.
SUMMARY OF THE INVENTION
[0012] The present invention provides a system and method of applying a developer to a photoresist material layer disposed on a semiconductor substrate. The developer system and method employ a developer plate having a plurality of apertures for dispensing developer. Preferably, the developer plate has a bottom surface with a shape that is similar to the wafer. The developer plate is disposed above the wafer and substantially and/or completely surrounds the top surface of the wafer during application of the developer. A small gap is formed between the wafer and the bottom surface of the developer plate. A small gap is defined as a gap having a size from about 0.5 to about 5 mm. The wafer and the developer plate form a parallel plate pair, such that the gap can be made small enough so that the developer fluid quickly fills the gap. The developer plate is disposed in very close proximity with respect to the wafer, such that the developer is squeezed between the two plates thereby spreading evenly the developer over the wafer. Preferably, the developer plate and the wafer are rotated in the same direction at the same speed or frequency so that the amount of agitation can be controlled to strictly a radial mode. Alternatively, the developer plate and the wafer can be rotated in the same direction at different speeds and frequencies to increase the agitation of the developer. Furthermore, the developer plate and the wafer can be rotated in different directions at the same or different speeds and frequencies to increase the agitation of the developer.
[0013] Moreover, the proximity of the developer plate to the wafer during application and the size of a plurality of apertures in the developer plate provides for improved localization with respect to development of the photoresist material layer. Since very little surface area of the photoresist material layer is exposed, evaporation rates can be minimized with respect to conventional development, thus improving temperature control. Additional improvements in temperature control can be obtained by heating the developer plate. In one aspect of the invention, the developer plate is also provided with a washing or rinsing solution for washing or rinsing the developed photoresist from the wafer. The developer plate can include separate apertures and supply mechanisms for supplying the washing solution to isolate the developer from the washing solution. Since the wafer is covered during spin rinsing, splashback effects are minimized.
[0014] Another aspect of the invention relates to providing a differential voltage across the developer plate and a wafer or a wafer support (e.g., a wafer chuck). The differential voltage causes the photoresist resin material to retain a negative charge. During the development process, irradiated or nonirradiated portions of the photoresist are developed. An electric field generated by the differential voltage facilitates transport of the negatively charged developed resin material out of small areas and voids, so that undeveloped portions of the photoresist resin selected for development may be exposed to the developer material. Therefore, improved development of the entire photoresist layer is the result.
[0015] One aspect of improved localization with respect to development of the photoresist material layer involves better CD control. Improved CD control is obtainable employing the present invention since the developer is dispensed and spread relatively equally over the photoresist surface. That is, substantially the same CD control is achieved at various locations across the photoresist surface.
[0016] To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of the invention. These embodiments are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 a illustrates a front view of a developer material and washing solution material application system in accordance with the prior art;
[0018] [0018]FIG. 1 b illustrates a top view of the developer material and washing solution material application system illustrated in FIG. 1 a in accordance with the prior art;
[0019] [0019]FIG. 2 a illustrates a bottom view of a development system in accordance with the present invention;
[0020] [0020]FIG. 2 b illustrates a side view of the development system of FIG. 2 a in accordance with the present invention;
[0021] [0021]FIG. 3 a illustrates a bottom view of a development system in accordance with the present invention;
[0022] [0022]FIG. 3 b illustrates a side view of the development system of FIG. 3 a in accordance with the present invention;
[0023] [0023]FIG. 4 is a representative schematic block diagram of a heating and monitoring system in accordance with one particular aspect of the present invention;
[0024] [0024]FIG. 5 a illustrates a front view of a developer plate and wafer in the same direction in accordance with the present invention;
[0025] [0025]FIG. 5 b illustrates a front view of a developer plate and wafer rotating in opposite directions in accordance with the present invention;
[0026] [0026]FIG. 6 a illustrates a front view of a differential voltage being applied across a developer plate and wafer rotating in the same direction in accordance with the present invention;
[0027] [0027]FIG. 6 b illustrates a front view of a developer plate and wafer having an electric field therebetween in accordance with the present invention;
[0028] [0028]FIG. 7 is a flow diagram illustrating one specific methodology for carrying out a development process in accordance with the present invention;
[0029] [0029]FIG. 8 is a flow diagram illustrating another specific methodology for carrying out a development process in accordance with the present invention; and
[0030] [0030]FIG. 9 is a flow diagram illustrating a specific methodology for carrying out a development process during the presence of an electric field between the developer plate and photoresist material layer in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. The present invention will be described with reference to a system and method of applying a developer to a photoresist material layer disposed on a semiconductor substrate. The system and method employ a developer plate having a plurality of apertures for dispensing developer. The developer plate is disposed in close proximity to the photoresist material layer during application and the developer plate and the substrate form a parallel plate pair. The developer plate remains engaged with the photoresist material layer during the development process mitigating any waste of developer and maximizing development efficiency. Therefore, less developer is required to develop a photoresist material layer. A differential voltage is applied across the developer plate and wafer facilitating the development process. It should be understood that the description of these embodiments are merely illustrative and that they should not be taken in a limiting sense.
[0032] [0032]FIGS. 2 a and 2 b illustrate a development application system 40 . The development application system 40 includes a developer supply system 43 , a plurality of supply nozzle assemblies 45 and a parallel developer plate 41 . The parallel developer plate 41 includes a plurality of apertures 47 extending therethrough for applying a developer to a photoresist material 42 that has been spin coated onto a wafer 44 . The wafer 44 is vacuum held onto a rotating chuck 46 . The wafer 44 is spin rotated by a shaft 48 driven by a motor (not shown), so that a photoresist material can be applied to the wafer 44 to form a uniform film or layer of photoresist material 42 over the wafer 44 . After the photoresist material is baked and/or dried, suitable photolithographic techniques (e.g., irradiation, development ) may be performed to form a patterned photoresist material layer.
[0033] The developer plate 41 forms a parallel plate pair with the wafer 44 during application of the developer. The developer supply system 43 can be provided with a supply of concentrated developer (not shown) and can be provided with a supply of water (not shown) for allowing variation of the concentration of the developer. The supply nozzles provide the developer plate 41 with a volume of developer for application to the patterned photoresist material layer 42 . The developer plate 41 can include an on/off shut off plate (not shown) or the like therein for controlling the application of the developer. The on/off shut off plate allows for the developer to be evenly spread throughout the developer plate 41 prior to applying the developer to the photoresist material layer 42 . The developer plate 41 is disposed in very close proximity with respect to the wafer 44 , such that the developer is squeezed between the two plates (i.e., the developer plate 41 and the wafer 44 ) thereby spreading evenly the developer over the wafer. Typically, a gap 50 between the developer plate 41 and the wafer 44 is from about 0.5 to about 5 mm. In another aspect of the invention, the gap 50 is from about 1 to 3 mm. Preferably, the gap 50 is about 2 mm. Since the developer film is stagnant, less splashing occurs and a more uniform development of the wafer is the results. Furthermore, the proximity of the developer plate 41 to the wafer 44 during application and the size of the plurality of apertures provides for improved localization with respect to development of the photoresist material layer 42 . In this connection, improved CD control is achievable; and in particular, CD control is uniform across the wafer.
[0034] [0034]FIGS. 3 a and 3 b illustrate an alternate development application system 60 . The development application system 60 includes a developer supply system 63 , a single central developer supply nozzle 65 , a washing solution supply nozzle 65 ′ and a parallel developer plate 61 . The parallel developer plate 61 includes a plurality of apertures 67 extending therethrough for applying a developer to a photoresist material 62 that has been spin coated onto a wafer 64 . The developer plate 61 also includes a plurality of apertures 67 ′ for applying a washing solution to the photoresist material 62 after the material is developed by the developer. The developer apertures 67 and the washing solution apertures 67 ′ are isolated by one another through a series of chambers (not shown).
[0035] The developer plate 61 forms a parallel plate pair with the wafer 64 during application of the developer and/or washing solution. The developer supply system 63 is provided with a supply of concentrated developer (not shown) and a supply of water (not shown) for allowing variation of the concentration of the developer. The nozzles provide the developer plate 61 with a volume of developer for application to the patterned photoresist material layer 62 . The developer plate 61 is disposed in very close proximity with respect to the wafer 64 , such that the developer is squeezed between the two plates (i.e., the developer plate 61 and the wafer 64 ) thereby spreading evenly the developer over the wafer. Preferably, a gap 69 between the developer plate 61 and the wafer 64 is about 2 mm. The use of a single central nozzle provides for easier implementations of heat lamps or the like for heating the developer plate 61 . The washing solution nozzle 65 ′ is supplied with a supply of washing solution (not shown). Splashback effects are prevented due to the close proximity of the plate 61 to the photoresist material 62 .
[0036] Referring initially to FIG. 4, a system 70 for heating substantially uniformly the developer plate 61 is shown. The system 70 includes a plurality of heat lamps 86 which are selectively controlled by the system 70 so as to facilitate uniform heating of the developer plate 61 . At least one optical fiber 88 projects radiation onto a portion of the developer plate 61 . Radiation reflected from the developer plate 61 is processed by a temperature measuring system 80 to measure at least one parameter relating to the temperature of the developer plate 61 . The reflected radiation is processed with respect to the incident radiation in measuring the temperature.
[0037] The measuring system 80 can include an interferometry system or a spectrometry system. It is to be appreciated that any suitable interferometry system and/or spectrometry system may be employed to carry out the present invention and such systems are intended to fall within the scope of the hereto appended claims. Interferometry systems and spectrometry systems are well known in the art, and therefore further discussion related thereto is omitted for sake of brevity.
[0038] A light source 84 of monochromatic radiation such as a laser provides radiation to the at least one optical fibers 88 via the measuring system 80 . Preferably, the radiation source 84 is a frequency stabilized laser however it will be appreciated that any laser or other radiation source (e.g., laser diode or helium neon (HeNe) gas laser) suitable for carrying out the present invention may be employed.
[0039] A processor 72 receives the measured data from the measuring system 80 and determines the temperature of the developer plate 61 . The processor 72 is operatively coupled to system 70 and is programmed to control and operate the various components within the developer system 70 in order to carry out the various functions described herein. The manner in which the processor 72 can be programmed to carry out the functions relating to the present invention will be readily apparent to those having ordinary skill in the art based on the description provided herein.
[0040] A memory 74 which is operatively coupled to the processor 72 is also included in the system 70 and serves to store program code executed by the processor 72 for carrying out operating functions of the system 70 as described herein. The memory 74 includes read only memory (ROM) and random access memory (RAM). The ROM contains among other code the Basic Input-Output System (BIOS) which controls the basic hardware operations of the system 70 . The RAM is the main memory into which the operating system and application programs are loaded. The memory 74 also serves as a storage medium for temporarily storing information such as developer plate temperature, temperature tables, interferometry information, spectrometry information and other data which may be employed in carrying out the present invention. For mass data storage, the memory 74 may include a hard disk drive (e.g., 10 Gigabyte hard drive).
[0041] Power supply 82 provides operating power to the system 70 . Any suitable power supply (e.g., battery, line power) may be employed to carry out the present invention.
[0042] The processor 72 is also coupled to a volume and mixture control system 78 . The volume and mixture control system 74 is operatively coupled to the developer nozzle 65 , which applies developer to the photoresist material 62 and the washing solution nozzle 65 ′ for rinsing the developed photoresist from the photoresist material layer 62 . It is to be appreciated although a single nozzle 65 is illustrated, the developer application system 70 can be employed that implements a plurality of similar nozzles for supplying developer and/or a rinse material to the developer plate 61 . The volume and mixture control system 74 can select between supplying developer or a rinse material to rinse the developer from the developed photoresist material 62 . The volume and mixture control system 74 can also control the volume of developer and/or rinse material supplied to the developer plate 61 .
[0043] [0043]FIG. 5 a illustrates one particular aspect of the invention with respect to movement of the developer plate 61 and the wafer 64 during application of developer on the photoresist layer 62 . A supply of developer (not shown) is provided to a supply tube 115 disposed in a developer rotation shaft 110 . In one aspect of the invention, the developer rotation shaft rotates the developer plate 61 in the same direction and at the same frequency or speed as the shaft 68 rotates the wafer 64 . This provides for controlling and limiting the agitation of the developer and photoresist material to mostly the radial direction. Alternatively, FIG. 5 b illustrates an example where the agitation of the developer and the photresist material is increased by rotating the developer plate 61 in the opposite direction with respect to the wafer 64 .
[0044] Although the developer plate 61 has been illustrated with respect to a circular surface covering the entire surface of the wafer 64 , it is to be appreciated that the size and shape of the surface is not limited to such, various shapes and sizes may be employed as long as the developer plate substantially covers the wafer 64 and that the gap between the developer plate 61 and the wafer 64 remains small. Additionally, although the developer plate 61 has been illustrated with respect to a developer plate 61 with a plurality of uniformly distributed apertures extending therethrough (e.g. a shower head like structure) a variety of aperture patterns may be employed. For example, an aperture pattern resembling a spiral with holes being larger with respect to the center of the developer plate may be employed in a situation where the developer plate remains stationary and the wafer rotates during application of the developer. Other aperture patterns may be employed based on the type and density of the developer and/or resist pattern.
[0045] [0045]FIG. 6 a illustrates one particular aspect of the invention with respect to facilitation of the development process by providing a differential voltage across the developer plate 61 and the wafer 64 during application of developer on the photoresist layer 62 . A voltage source 116 has a positive terminal coupled to the developer plate 61 and a negative terminal coupled to the wafer 64 . Prior to the development process the potential voltage from the developer plate 61 to the wafer 64 causes the photoresist layer 62 to retain a negative charge. Other mechanisms may be provided to negatively charge the photoresist layer. A supply of developer (not shown) is provided to a supply tube 15 disposed in a developer rotation shaft 110 . The developer rotation shaft rotates the developer plate 61 as the shaft 68 rotates the wafer 64 . This provides for controlling and limiting the agitation of the developer and photoresist material to mostly the radial direction. As illustrated in FIG. 6 b , an electric field is provided between the developer plate 61 and the wafer 62 by the differential voltage between the plates. The electric field 118 facilitates transport of the developed portions of the photoresist material, for example, during spinning so that undeveloped portions selected to be developed (e.g., irradiated or nonirradiated portions) can be further exposed to the developer.
[0046] [0046]FIG. 7 is a flow diagram illustrating one particular methodology for carrying out the development process in accordance with the present invention. In step 120 , the developer plate 61 is heated to a desired temperature. In step 130 , the developer plate 61 and the wafer 64 are spun in the same direction at the same rotational speed and developer is applied. In step 140 , the process waits for the developer to coat the photoresist material layer 62 and the developer plate and the wafer 62 are stopped from spinning. In step 150 , the process waits for the developer to develop the photoresist material layer 62 . The wafer is then rinsed with a washing solution material until the wafer is completely rinsed in step 160 . In step 170 , the developer plate 61 is moved from the top of the wafer 64 and the wafer 64 is advanced to the next process.
[0047] [0047]FIG. 8 is a flow diagram illustrating another methodology for carrying out the development process in accordance with the present invention. In step 220 , the developer plate 61 is heated to a desired temperature. In step 230 , the developer plate 61 and the wafer 64 are spun in different directions at the same rotational speed and developer is applied. In step 240 , the process waits for the developer to coat the photoresist material layer 62 and the developer plate and the wafer 62 are stopped from spinning. In step 250 , the process waits for the developer to develop the photoresist material layer 62 . The wafer is then rinsed with a washing solution material until the wafer is completely rinsed in step 260 . In step 270 , the developer plate 61 is moved from the top of the wafer 64 and the wafer 64 is advanced to the next process.
[0048] [0048]FIG. 9 is a flow diagram illustrating another methodology for carrying out the development process by employing a differential potential across the developer plate and the wafer in accordance with the present invention. In step 320 , a differential voltage is applied across the developer plate 61 and the wafer 64 producing a negatively charged photoresist layer in the presence of an electric field. In step 330 , the developer plate 61 and the wafer 64 are spun as developer is applied. In step 340 , the process waits for the developer to coat and develop the photoresist material layer 62 and also until all of the negatively charged developed photoresist has been transported. In step 350 , spinning of the developer plate 61 and the wafer 64 is stopped. The wafer is then rinsed with a washing solution material until the remaining developed photoresist has been removed in step 360 . In step 370 , the developer plate 61 is moved from the top of the wafer 64 and the wafer 64 is advanced to the next process.
[0049] What has been described above are preferred embodiments of the present invention. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the present invention, but one of ordinary skill in the art will recognize that many further combinations and permutations of the present invention are possible. Accordingly, the present invention is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims.
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A system and method is provided for applying a developer to a photoresist material layer disposed on a semiconductor substrate. The developer system and method employ a developer plate having a plurality of apertures for dispensing developer. Preferably, the developer plate has a bottom surface with a shape that is similar to the wafer. The developer plate is disposed above the wafer and substantially and/or completely surrounds the top surface of the wafer during application of the developer. A small gap is formed between the wafer and the bottom surface of the developer plate. The wafer and the developer plate form a parallel plate pair, such that the gap can be made small enough so that the developer fluid quickly fills the gap. A differential voltage is applied to the developer plate and the wafer causing an electric field to be formed in the gap. Transportation of negatively charge photoresist material is facilitated by exposure to the electric field during the development process.
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FIELD OF THE INVENTION
The present invention is directed to a method and apparatus for improving filler retention in papermaking and, in particular, to a method and apparatus which diverts a portion of the pulp slurry for filler and retention aid addition thereto prior to feeding the pulp slurry to a papermaking machine.
BACKGROUND ART
In the art of papermaking, a well known incentive includes increasing the amount of filler in the final paper product. This incentive can be driven by both a shortage of pulp for papermaking and pulp prices.
One method for increasing the filler content in paper is the use of chemical retention aids. Retention aids typically permit an increase in filler content by modifying the bonding relationship between the fiber in the pulp and the filler. Typically, filler particles are much smaller than most pulp fibers and are not effectively retained by filtration through the pulp matte as it forms on a papermaking machine. Retention aids include cationic starches, charge-biasing polymeric types such as amine or quaternary ammonium groups and polymeric bridging agents such as ionic, cationic or anionic polymers. Often times, different retention aids are added for synergistic improvements such as using both a low molecular weight cationic polymer and a high molecular weight anionic polymer.
FIG. 1 shows a typical prior art papermaking method using retention aids to increase filler retention. A portion of an overall papermaking apparatus is designated by the reference numeral 10 and is seen to include a thick stock machine chest 1, a fan pump 3, a head box 5, white water silo 7 and a papermaking machine 9. It should be understood that since this apparatus is well known in the art, a further detailed description of the components upstream of the machine chest 1 and downstream of the papermaking machine 9 are not included or deemed necessary for understanding of the invention.
In use, a filler 11 is added to a pulp slurry 13 to form a filler-containing pulp slurry 15 or the filler 11 is fed directly to the thick stock machine stock 1 or fan pump 3. The thick stock 17 is then fed to the fan pump 3. The white water recycle 19 from the silo 7 is also fed to the fan pump 3 to form the thin stock 21. The retention aid 23 is then added to the thin stock upstream of the head box 5 to increase retention of the filler during papermaking, typically past the screens and cleaners.
In a similar prior art system as described in the publication entitled "Three Developments at Wolvercote Paper Mill" by M. C. Riddell et al., Paper Technology and Industry, April, 1976, pages 76-80, the retention aid is a high molecular weight synthetic polymer with a specific charge density and the filler is a clay or calcium carbonate. Addition of the retention aid to the filler-containing pulp slurry results in preflocculation of the filler. Adding the retention aid at the head box minimizes shearing of the preflocculated filler and possible lowering of filler retention.
One problem with these types of papermaking systems occurs when using a pulp containing high amounts of anionic trash. When adding a cationic retention aid to a pulp containing high amounts of anionic trash, the cationic retention aid tends to become neutralized by the anionic trash present in the pulp. With this neutralization of the retention aid, the filler retention during papermaking is reduced.
A prior art solution to this problem has been the addition of more cationic retention aid. More specifically, a cationic coagulant is added to the pulp slurry upstream to the filling addition followed by addition of a retention aid at the head box after filler addition. This approach is not only expensive, with as much as $50.00 of chemical costs being added to the cost of paper, but can also be difficult to run on the paper machine and can lead to significant down time on the machine without very close machine monitoring. Moreover, with the increased operating costs, approaches of this type are usually limited to a special grade of paper wherein the manufacturer can recoup the increased operating costs through the value of the final paper product.
Another problem with the prior art system discussed above wherein preflocculation of the filler occurs due to the retention aid addition is the formation of large agglomerates which are mechanically entrapped in the paper web. Although filler retention as high as 99% can be obtained, this approach leads to very large particles which create a mottled appearance on the sheet and could also lead to dusting problems.
One solution to the creation of a mottled appearance on the sheet is applying shear to the preflocculated filler particles to reduce their size and effect on sheet appearance. However, this shearing process is difficult to control and also greatly reduces the retention of the filler material.
Referring now to FIG. 2, the effective shear on the retention of a preflocked filler clay and a standard retention aid treatment is shown. As expected, the preflocked filler treatment shows higher ash retention percentages than the standard treatment at low shear rates. However, increasing the shear rate to improve the surface appearance adversely effects the percent ash retained of the preflocked filler material. In fact, by the time sheet appearance is acceptable by increasing the shear rate to around 1000 RPM, the retention of filler is only marginally better for the preflocked filler than the standard treatment. However, if sheet appearance is not a problem, preflocked fillers can produce a significant cost savings over the standard treatment. However, the use of preflocked fillers is limited when seeking acceptable sheet appearance.
In view of the disadvantages noted above in the prior art, a need has developed to provide an improved method of maintaining or increasing filler retention while using lower amounts of retention aids and maintaining acceptable surface appearance.
In response to this need, the present invention solves the problems of the prior art discussed above by providing both a method and apparatus for improved filler retention in papermaking which not only reduces the amount of retention aids and cationic coagulants used but also maintains acceptable surface appearance in the paper product and provides high levels of filler retention.
SUMMARY OF THE INVENTION
Accordingly, a first object of the present invention is to provide a method and apparatus which increases filler retention in papermaking.
A further object of the present invention is to provide a method and apparatus which combines both improved filler retention and improved sheet appearance in papermaking, using lower amounts of retention aids and cationic coagulants.
Yet another object of the present invention is to provide a process that combines all of high filler retention levels, low retention aid use and good sheet appearance in papermaking.
The present invention, as another object, provides an apparatus for improving the filler retention in papermaking without sacrificing sheet appearance and increasing operating costs.
Other objects and advantages of the invention will be apparent as a description thereof proceeds.
In satisfaction of the foregoing objects and advantages, the present invention is an improvement over papermaking methods wherein fillers and retention aids are added to a pulp slurry and the filler and retention aid-containing pulp slurry is then fed to a paper machine. According to the inventive method, the pulp slurry is first separated into first and second streams prior to filler and retention aid addition. The filler and retention aid are then added to one of the two streams. The stream containing the filler and retention aid is then added back to the second stream to be further processed in the papermaking method. By practicing the inventive method, the adverse affects of high amounts of anionic trash in the pulp slurry are minimized.
The term "retention aid" is intended to encompass retention systems using single or multiple polymers systems such as cationic polymers including natural and synthetic materials, i.e., starch, anionic polymers, cationic polymers and those systems using microparticle technology based on silica or bentonite, e.g. Composil™. Any retention system capable of use in conventional or other types of pulp flow schemes would be suitable for use according to the invention.
Preferably, the pulp slurry is fed to a thick stock machine chest of a papermaking system and the slurry is separated into the first and second streams from the machine chest or downstream thereof. The first stream after receiving the filler and retention aid addition can then be merged with the second stream upstream of a fan pump. Alternatively, the filler and retention aid-containing first stream can be merged with the aid of an auxiliary fan pump into the thin stock pulp slurry exiting the fan pump, upstream of the papermaking system head box.
The filler can be one of a clay, calcium carbonate, talc, zinc sulfate, magnesium hydroxide, aluminum trihydrate, barium sulfate, calcium sulfate, titanium dioxide, precipitated silicate or silicas or any other known filler useful in papermaking. The retention aid can also be any known retention aid such as a cationic, anionic or non-ionic type or a combination thereof.
The separation of the pulp slurry into the two streams is preferably based on the percent amount of filler in the final paper product.
The invention is also an improvement over known apparatus. In these known apparatus, a thick stock machine chest is provided along with a fan pump, a head box, a papermaking machine and a water recycle system which recirculates white water from the papermaking machine to the fan pump. In this known system, a thick stock pulp flow line interconnects the thick stock machine chest and the fan pump and a thin stock pulp flow line interconnects the fan pump and a head box. The inventive apparatus provides a second thick stock pulp flow line which takes a portion of thick stock paper pulp for treatment, either from the machine chest or downstream thereof. Means for adding a filler and a retention aid to the second thick stock pulp flow line are provided. The thick stock pulp flow containing the filler and the retention aid is then merged with the other thick stock pulp flow line or the thin stock pulp flow line downstream of the fan pump. The merging of the thick stock pulp flow containing the filler and retention aid can be done using valves or other conventional components.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to the drawings of the invention wherein:
FIG. 1 is a schematic block diagram of a portion of a prior art papermaking system;
FIG. 2 is a graph comparing the effective shear on preflocked filler and percent ash retention;
FIG. 3 is a schematic block diagram of a preferred embodiment of the inventive apparatus and method; and
FIG. 4 is a graph 4 showing the effect of filler/fiber ratio on sheet appearance.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to FIG. 3, a preferred embodiment of the inventive method and apparatus is generally designated by the reference numeral 20. In this embodiment, similar components are used as depicted in FIG. 1. More specifically, a thick stock machine chest 1, a fan pump 3, a head box 5, a white water recycle silo 7 and a papermaking machine 9 are provided. A pulp slurry 13 is provided to the machine chest.
In accordance with the invention, the thick stock exiting the machine chest is split into two thick stock pulp slurry streams 17' and 24. Thick stock pulp slurry stream 17' is directed to the fan pump 3. The thick stock pulp slurry stream 24 receives the filler 11 and retention aid 23 in the desired amounts. With the addition of the filler 11 and retention aid 23, a filler and retention aid-containing thick stock pulp slurry 25 is formed. The pulp slurry 25 can then be split into streams 27 and 29. The pulp slurry 27 merges with the thick stock pulp slurry 17' and the white water recycle 19 upstream of the fan pump 3. Alternatively, the filler and retention aid-containing pulp slurry 25 can be added via stream 29 to the thin stock pulp slurry 21' upstream of the head box 5. In this mode, a fan pump 3' and white water recycle 19' can be disposed in stream 29 to build pressure in the stream 29, if necessary. Another fan pump could also be in stream 27, if necessary. Although two streams 27 and 29 are depicted, only a single split stream could be used and merged with the pulp slurry either upstream or downstream of the fan pump.
Valves 31 and 33 can be used to control diversion of the stream 25 to either the thick stock stream 17' or the thin stock stream 21'. Of course, any other means for controlling the flow between streams 27 and 29 can be utilized as would be known to those skilled in the art. In addition, overall control schemes can also be utilized for filler and retention aid addition as well as control of the flow rate in streams 24, 17', 27 and 29 as would also be within the skill of the art. If desired, more than two streams could emanate from the thick stock machine chest. In this mode, two of the three streams could receive filler and/or retention aid to improve filler retention percentage, lower retention aid cationic coagulant consumption and provide acceptable sheet appearance. Further, the thick stock could be split downstream of the machine chest 1 as represented by feed line 26.
Adding the desired amount of filler and retention aid to only a portion of the thick stock pulp slurry exiting the machine chest 1 provides significant benefits in the overall papermaking process. First, the retention aid 23 sees lesser amounts of the anionic trash present in the pulp slurry 13. Thus, lower amounts of cationic coagulant are needed when processing pulp containing high levels of anionic trash.
In addition, by segregating or splitting a small portion of the thick stock pulp slurry, more filler is needed to obtain the same overall ash level on the machine. Consequently, the filler and fiber are subjected to a preflocked situation in the stream 25. By concentrating the solution of fiber in the pulp slurry and the filler, the kinetics of reaction with the retention aid are shifted in favor of the filler instead of the dissolved colloidal material, i.e, the anionic trash, that would foul the polymeric retention aid 23.
This inventive method has applications in papermaking systems using any filler ranging from kaolin clay, calcium carbonate and talc to more exotic fillers such as aluminum trihydrate, magnesium hydroxide, calcined clay and precipitated silicas and silicates. Typical retention aids systems include Betz 1290 (anionic acrylamide) and Betz 230 (quaternary amine). Other polymers have also been shown to be applicable, ranging from Betz 8905 (branched cationic co-polymer), Nalco 7607 (quaternary amine) and Nalco 625 (anionic polyacrylamide), Nalco 713 (cationic polyacrylamide), polyethylene imine (PEI) from BASF, cationic starch and alum. Non-ionics, such as (Polyethylene oxide) would also work. The choice of the polymer is governed by the pulp system into which it is being introduced. Other retention aids are known in the art, can also be used.
Using the split flow of the invention, a significant increase in first pass retention is achieved in the papermaking system along with a significant reduction in retention aid consumption. In addition, the inventive system requires no more monitoring than a traditional system adding retention aids upstream of the head box.
A further benefit of the invention is realized on paper machines that contain high amounts of residual anionic material from ink that is carried over from the recycling process. If retention is increased on these types of machines, brightness is lost due to the retention of more of the residual ink. By using the split pulp flow system of the invention, the amount of the residual ink that is retained could be significantly reduced allowing simultaneous brightness gains and retention in these grades.
The flow rate of the stream 24 is dependent on several variables. For example, the flow rate and level of filler addition could be a function of the filler content in the pulp slurry going to the papermaking machine 9. In this instance, the flow rate for the stream 24, e.g. the secondary flow, could be determined by the following equation:
F=((C*T)/M)
where F =the secondary flow rate (Tons/hr.).
C =the percent of filler desired in the final sheet. (Normal ranges from 1 to 40%).
T =total production rate on single ply machines or production rate of a single ply on a multi-ply machine. Normal ranges from 1 ton/hr to 75 tons/hr. and
M =the % filler in the secondary flow. Normal ranges 25 to 50%. (This is governed by the amount of anionic trash in the system, e.g., more or less than the normal 25-50%.)
Table 1 exemplifies three different examples for determining the split stream or secondary flow rate for different total production rates, different filler percents in the final sheet and different filler percentages in the secondary flow. Of course, other scenarios could be contemplated by those skilled in the art. It is believed that the overall ranges could include the following: 1 to 40% of percent filler in the final sheet product, 25 to 50% filler in the secondary flow, up to 100 tons/hr. as the total production rate.
TABLE 1______________________________________ Case 1 Case 2 Case 3______________________________________Total Production (T) 75 Tons/hr. 45 Tons/hr. 15 Tons/hr.Filler in Sheet, % (C) 20 10 5Filler in Secondary Flow, 30 40 50% (M)Secondary Flow Rate (F) 50 Tons/hr. 11.25 Tons/hr. 1.5 Ton/hr.______________________________________
As described above, the inventive process is especially beneficial in systems containing anionic trash, that use an expensive specialty filler and/or use dirty recycled furnish. Quite unexpectedly, using the split stream approach results in simultaneous reduction in chemical retention aid usage, increased filler retention and acceptable sheet appearance.
Table 2 details an experimental study comparing the inventive process with a prior art system using no retention aid and one using two pounds of retention aid retention is increased and retention aid consumption is reduced when compared to the prior art systems.
TABLE 2______________________________________Retention of Filler Using New ProcessPolymer Dosage Prior Art Control______________________________________Betz 1290 0.24 0.18 0.13 0.10 Control NoBetz 230 0.36 0.26 0.20 0.16 2.0#/Ton Polymer(#/ton) Pulp.sup.1Estimated 0.60 0.44 0.33 0.26 2.0 --Polymer Cost$/ton PaperFirst Pass 49.9 45.0 38.3 33.1 16 9.1Ash Retention %Fiber/Filler 70/30 70/30 70/30 60/40 88/12 88/12Ratio, %.sup.2______________________________________ *sheets with acceptable appearance were reported. Higher Retention can be obtained by sacrificing appearance. .sup.1 Polymer added without split stream. .sup.2 Fiber/Filler Ratio is for the split flow only. This number will be governed by the amount of fiber diverted to the secondary stream.
FIG. 4 graphically demonstrates the results exemplified in Table 2. Again, significantly improved first pass ash retention rates are achieved with lower retention aid consumption and acceptable sheet appearance over prior art systems. This comparative study confirms the unexpected results associated with the inventive split stream process and apparatus.
Although conventional apparatus have been described using the inventive process, it should be understood that other types of apparatus could be used to achieve the split stream filler/retention aid treatment described above as would be known in the art.
As such, an invention has been disclosed in terms of preferred embodiments thereof which fulfill each and every one of the objects of the present invention as set forth hereinabove and provides a new and improved method and apparatus for papermaking.
Of course, various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. Accordingly, it is intended that the present invention only be limited by the terms of the appended claims.
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A method for improving retention of filler in papermaking systems includes a split stream feed to either the head box or fan pump of a papermaking system. The split stream divides the pulp flow into two streams, one stream having a retention aid and filler added thereto. The retention aid and filler-containing stream is then added back to the other stream upstream of the fan pump or head box. Treating only a portion of the overall pulp flow with the filler/retention aid lowers retention aid consumption, improves paper product appearance and maintains or increases filler retention during papermaking.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation application and claims priority under 35 U.S.C. 120 of international application PCT/EP2007/062970, filed Nov. 28, 2007 and published in English as WO/2008/065153, the content of which is hereby incorporated by reference in its entirety.
BACKGROUND
The discussion below is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter.
Aspects of the invention concern a lubrication seal. Such a seal is known from FR 2742837. The disadvantage of the known seal is that the second seal ring has to seal on the same sealing area as the first seal ring. The lubrication barrier is meant to have a long life expectancy and over a long operation period there might develop damage to the first sealing area. This means that if the lubrication barrier is leaking and the cause of leaking is damage to the first sealing area replacing the first seal ring by the second seal ring does not stop the leaking and does not bring the desired improvement.
SUMMARY
This Summary and Abstract are provided to introduce some concepts in a simplified form that are further described below in the Detailed Description. This Summary and Abstract are not intended to identify key features or essential features of the claimed subject matter, nor are they intended to be used as an aid in determining the scope of the claimed subject matter. In addition, the description herein provided and the claimed subject matter should not be interpreted as being directed to addressing any of the short-comings discussed in the Background.
A lubrication seal assembly such as an oil seal is described for providing a lubrication barrier to confine lubrication in a bearing with a first bearing ring and second bearing ring, comprising a support ring that rotates with one of the bearing rings, mounted in the support ring are a first seal ring and a second seal ring which seal rings are suitable for forming the lubrication barrier with a sealing surface that rotates with the other bearing ring and which support ring is displaceable from a first sealing position in which the first seal ring forms the lubrication barrier with a first sealing area and the second seal ring does not engage the sealing surface to a second sealing position in which the second seal ring forms the lubrication barrier. The sealing surface comprises a second sealing area that only cooperates with the second seal ring after the support ring is displaced into the second sealing position. By creating a new lubrication barrier with a new seal ring that seals on a new sealing area the lubrication barrier will function as completely new.
In accordance with an embodiment the second sealing area is at the side of the lubrication barrier nearest to the bearing when the support ring is in the first sealing position. In this way the second sealing area is protected from outside influences by the lubrication barrier so that damage to the second sealing area is prevented.
In accordance with an embodiment the first sealing area and the second sealing area have the same diameter and whereby the sealing surface has between the first sealing area and the second sealing area a groove with a width that is at least equal to the width of the second seal ring. In this way the first seal ring and the second seal ring can have the same dimensions which makes the support ring more compact and reduces costs.
In accordance with an embodiment the first sealing area and the second sealing area have different diameters. In this way it is avoided to make a groove m the sealing surface and the first seal ring can remain sealing against the sealing surface.
In accordance with an embodiment the material of the seal rings is polytetrafluoroethylene or a similar material. This material reduces friction between the sealing surface and the seal ring and so obtains an increased service life of the seal ring. In accordance with an embodiment the sealing areas are from tempered steel. This lengthens the service life of the sealing surface.
In accordance with an embodiment the sealing areas are part of a bearing ring. This makes it possible to make a compact bearing with a lubrication seal whereby the sealing areas can be made to the same quality as the surfaces of the bearing or if applicable the ball or roller track (s) of the bearing.
An aspect of the invention also concerns a wind turbine with a lubrication seal assembly. The maintenance costs of a wind turbine with a main bearing for supporting the blades are strongly influenced by the service costs of the main bearing. In the known wind turbines replacing the main bearings or the lubrication seals there of is very expensive. By using in the main bearing lubrication seals with increased life expectancy the service costs of the wind turbine are considerably improved.
BRIEF DESCRIPTION OF THE DRAWING
Hereafter the invention is explained by describing various embodiments of the invention with the aid of a drawing. In the drawing
FIG. 1 shows a side view of a wind turbine,
FIG. 2 shows a detailed section of a main bearing of the wind turbine of FIG. 1 with a first embodiment of an oil seal device,
FIG. 3 shows a detail of a second embodiment of an oil seal device in a first position, and
FIG. 4 shows a detail of the second embodiment of an oil seal device in a second position.
DETAILED DESCRIPTION
FIG. 1 shows a wind turbine that is placed on a tower 1 and that has a housing 2 . The housing 2 is ro-tatable around a vertical axis. A housing ring 4 is with one side attached to the housing 2 and at the other side to a main bearing 9 . A rotor R, comprising a hub 11 with blades 10 is attached to the main bearing 9 and can rotate around a centreline 3 . At the front side the hub 11 is covered by a cap 12 . A generator rotor 6 with permanent magnets 5 is attached via a generator flange 8 to the main bearing 9 and rotates with the rotor R. A generator stator 7 is mounted on the housing ring 4 . The permanent magnets 5 move along the windings of the generator stator 7 to generate electrical power. The housing 2 can rotate around the vertical axis so that the rotor R can be directed towards the wind.
The wind turbine is designed with a direct drive generator and the generator rotor 6 is directly driven by the rotor R. The main bearing is located between the housing ring 4 and the rotor R and is designed to absorb the gravitational and aerodynamic loads on the rotor R. The service life of the main bearing 9 determines to a large extend the service life of the wind turbine as replacing the main bearing 9 leads to high costs. In circumstances whereby the wind turbine is placed m difficult accessible locations, for instance at sea, replacing the main bearing 9 during service life must be avoided. The service life of the main bearing 9 depends to a large extend on the service life of the oil seals between the rotating parts and the stationary parts of the main bearing 9 . These oil seals are required to ensure that sufficient lubrication means such as oil remains in the main bearing 9 . For this application, only oil seals that are mounted as a full ring between a rotating part and a stationary part have a service life that is long enough. Oils seals that are assembled and welded to a full ring around a part always have the weld as a weak spot. This weld reduces the service life to an unacceptable low level and this design is therefore not suitable. The assembly and disassembly of oil seals as full rings generally requires extensive dismantling of the equipment so that extension of the service life of the oil seal device is strongly desired.
FIG. 2 shows the main bearing 9 , which is a ball bearing with balls 18 , whereby an oil seal device is mounted between a stationary inner ring 17 and a rotating outer ring 16 on both sides of the balls 18 . The inner ring 17 is mounted on a flange 26 of the housing ring 4 . The generator flange 8 and the hub 11 are mounted on the outer ring 16 . A support ring 14 is coupled to the outer ring 16 by bolts 13 . A cylindrical part 27 of the support ring 14 is located between the inner ring 17 and the outer ring 16 . A static seal 19 is mounted on the outer circumference of the cylindrical part 27 and seals the opening between the outer ring 16 and the support ring 14 .
On the inner circumference of the support ring 14 an interior seal 20 and an exterior seal 21 are mounted, whereby the interior seal 20 is nearest to the parts to be lubricated such as the balls 18 and the exterior seal 21 is nearest to the surroundings. The outer circumference of the inner ring 17 near the support ring 14 has an exterior sealing surface 28 and an interior sealing surface 29 which is nearest to the parts to be lubricated and between the exterior sealing surface 28 and the interior sealing surface 29 a groove 22 . The groove 22 has a depth that ensures that the interior seal 20 or the exterior seal 21 are free when located above the groove 22 and do not have any contact with the inner ring 17 .
In the position shown in FIG. 2 there is a spacer 15 between the support ring 14 and the outer ring 16 (via the generator flange 8 and the hub 11 ) and the support ring 14 is m a first position. In this first position of the support ring 14 the exterior seal 21 seals with a flexible sealing lip against the exterior sealing surface 28 . The interior seal 20 is above the groove 22 so that there is no contact between the stationary inner ring 17 and the flexible sealing lip of the rotating interior seal 20 . As the interior seal 20 is behind the exterior seal 21 it has no influence from any contamination or light and there is no wear on the lip of the interior seal 21 . This way the interior seal 20 remains ready for use and as long as it is m this first position, there is no diminishing of its service life. Also the interior sealing surface 29 is protected by the exterior seal 21 and remains ready for use.
After a period the end of the service life of the exterior seal 21 is detected by observing oil leakage between the sealing lip of the exterior seal 21 and the exterior sealing surface 28 . After determining that the exterior seal 21 is at the end of its service life the spacer 15 is removed and the support ring 14 is pushed inwards and fastened to the outer ring 16 with the bolts 13 (via the generator flange 8 or the hub 11 ). The support ring 14 is now in its second position.
In this second position, the flexible sealing lip of the interior seal 20 seals on the interior seal surface 29 and the flexible lip of the exterior seal 21 is free of the inner ring 17 as it is above the groove 22 . (In other embodiments it might be possible that the exterior seal 21 remains in sealing contact with the exterior sealing surface 28 .) As the service life of the interior seal 20 and the interior sealing surface 29 only starts after the support ring 14 is placed in the second position and the flexible sealing lip of the interior seal 20 contacts the interior seal surface 29 , the service life of the oil seal device is twice as long. In order to extend service life of the oil seals as much as possible the exterior sealing surface 28 and the interior sealing surface 29 are preferably from tempered steel and have a ground surface. This way the wear on the flexible sealing lip is reduced as much as possible. The interior seal 20 and the exterior seal 21 are made from flexible material such as rubber or preferably Teflon or similar material m order to obtain a service life that is as long as possible. The service life of an oil seal device that can be obtained m this application with a single seal is approximately 15-20 years, which is slightly less than its expected service life. By using the oil seal device with two oil seals that are in service one after the other the oil seal device is no longer a limiting factor on the service life of the wind turbine. It will be clear that m order to make it possible to displace the support ring 14 m axial direction towards the balls 18 the exterior sealing surface 28 and the interior sealing surface 29 must be provided with a gradual transition such as sloped and/or rounded surfaces in order to avoid damage to the flexible sealing lips of the interior seal 20 or the exterior seal 21 . Also the outer ring 16 must be provided with a sloped surface in order to avoid damage to the static seal 19 when the support ring 14 is brought between the inner ring 17 and the outer ring 16 . In the embodiment shown m FIG. 2 the main bearing 9 is shown as a double row ball bearing. It will be clear to the skilled man that the invention is applicable for other types of ball bearings and for roller bearings or for any other type of bearing. Also aspects of the invention is applicable for other applications such as an oil seal device between a rotating shaft and a housing, whereby the rotating shaft rotates in roller bearings or ball bearings or in any other type of bearing.
FIGS. 3 and 4 show a sealing between an inner ring 25 and an outer ring 23 which rotate relative one another. In this embodiment the support ring 14 is coupled to the outer ring 23 and the exterior sealing surface 28 and the interior sealing surface 29 are on the inner ring 25 . It will be clear that this situation is preferred, as grinding an outer surface is easier. However there might be embodiments whereby it is preferred to have the exterior sealing surface 28 and the interior sealing surface 29 on the inside surface of the outer ring 23 . In the embodiment shown in FIGS. 3 and 4 the support ring 14 is movable in axial direction m a chamber 24 which is in open connection with space in which the parts to be lubricated such as one or more bearings, gears etc. are located. By using the support ring 14 with the interior seal 20 and exterior seal 21 , a doubling of the service of the oil seal device is obtained.
In situations whereby an even longer service life is desirable it is possible to use three or more seal rings with two or more grooves, so that seal rings can be used one after the other. The different grooves will then have an increasing width, seen from the exterior, in order to ensure that after moving the support ring over a small distance to a next position a next seal ring contacts a next sealing surface that has not been used by any other seal ring.
In the described embodiments the interior sealing surface 28 and the exterior sealing surface 29 have the same diameter and also the interior seal 20 and the exterior seal 21 have the same diameter. The same effect of using one oil seal after the other can be obtained without a groove 22 when the interior seal 20 and the interior sealing surface 29 have a slightly larger diameter than the exterior seal 21 and exterior sealing surface 28 . In this way the support ring 14 also has a first position in which the exterior ring 21 seals and a second position in which also the interior ring 20 seals.
Although the subject matter has been described in language specific to certain compositions, structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific compositions, features or acts described above as has been determined by the courts. Rather, the specific compositions, features and acts described above are disclosed as example forms of implementing the claims. Furthermore, the description herein is provided for purposes of understanding and that the components or functions performed described can be separated or grouped in other ways, if desired.
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A lubrication seal such as an oil seal is described for providing a lubrication barrier to confine lubrication in a bearing with a first bearing ring and second bearing ring, comprising a support ring that rotates with one of the bearing rings, mounted in the support ring are a first seal ring and a second seal ring which seal rings are suitable for forming the lubrication barrier with a sealing surface that rotates with the other bearing ring and which support ring is displaceable from a first sealing position in which the first seal ring forms the lubrication barrier with a first sealing area and the second seal ring does not engage the sealing surface to a second sealing position in which the second seal ring forms the lubrication barrier. The sealing surface comprises a second sealing area that only cooperates with the second seal ring after the support ring is displaced into the second sealing position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to a host controller for use with a bus and a host in a digital system, such as a printer. More particularly, this invention relates to a host controller for use with a bus and a host that having a start of frame packet generator to relax frame timing of packet generation sequences.
2. The Prior Art
The personal computer industry has recently defined a new peripheral bus architecture and protocol, known as a Universal Serial Bus (USB). The architecture and protocol of the USB are defined in Compaq, et al., “Universal Serial Bus Specification”, Rev. 1.1 (Sep. 23, 1998), and as used herein, a Universal Serial Bus is any bus which substantially conforms to that specification or to any subsequent revision thereof. Universal Serial Bus has also been utilized in other digital systems such as printers.
A Universal Serial Bus is organized in a “tiered star” topology, with a hub at the center of each star. A host controls the bus, and usually is connected immediately to a root hub. One or more “USB devices” are connected in a star topology to the root hub, and such USB devices can include keyboards, mice, joysticks, fax/modems, telephony devices, and so on. The term “USB device” as used herein also includes further hubs, which may themselves constitute the center of a topological star of further USB devices. Thus, each USB device is separated on the bus from the host by some number of hubs in the serial pathway between the host and the device. The USB specification specifies a maximum topology in which no device is separated from the host by more than six hubs including the root hub.
The USB specification allows users to add and remove USB devices from the bus at any time. Whenever a hub detects the addition or removal of a device, it so notifies the host, which then determines the new USB topology in a procedure known as enumeration.
Data is transferred on a Universal Serial Bus within one millisecond intervals called frames. Each frame begins with a “start of frame” (SOF) token or packet, issued by the host at one millisecond intervals and concludes with an “end of frame” (EOF) interval, during which no device is permitted to drive the bus. The intervening portion of each frame is referred to herein as a window during which bus transactions can take place.
The USB specification supports four different dataflow models, depending on the needs of each particular endpoint. An endpoint is a logical target within a device.
The four dataflow models are control transfers, bulk data transfers, interrupt data transfers and isochronous data transfers.
Control transfers are used for device configuration and can also be used for other device-specific purposes. Data delivery for control transfers is lossless.
Bulk transfers are usually used for larger amounts of data, such as for printers or scanners. Data delivery for bulk transfers is lossless, but the bandwidth that it occupies can be whatever is available and not being used for other transfer types.
Interrupt transfers are typically small, and may be presented for transfer by a device at any time. The device specifies a minimum rate (maximum number of frames of delay) at which the USB must deliver the data. Data delivery is lossless.
Isochronous transfers are for real time, time-sensitive delivery of data. An example of isochronous data is audio information. Such data must be delivered at the appropriate time, or errors are likely to result due to buffer or frame underruns or overruns. The Universal Serial Bus specification ensures timely delivery of isochronous data by assigning specific frame numbers to the data units to be transferred; if a data unit cannot be transferred in its designated frame number, the data unit is discarded.
According to the USB specification, higher level software in the host passes “transfer sets” to a host controller (which may be hardware and/or software), which divides the transfer sets into “transactions”, each having a data payload size which is no greater than a predetermined maximum size for each of the four data transfer types. It is then up to the host controller to dynamically schedule these transactions for execution on the bus, in accordance with a number of rules. First, all isochronous transactions designated for a particular frame number must take place during that frame number or be discarded. Second, all interrupt transactions must take place within the time specified by the device. Third, all transactions to a particular endpoint must take place in the same sequence with which they are provided to the host controller, although there is no requirement that transactions destined for different endpoints take place in the same sequence with which they are provided to the host controller. Fourth, all transactions in a frame must complete before the EOF region of the frame.
As discussed above, USB uses 1 ms frames for bandwidth allocation and synchronization of devices on the bus. A USB host transmits an SOF packet every 1 ms at the beginning of each frame. The USB specification states that the frame interval must be 1.000 ms±500 ns. However, this tight tolerance on the frame interval is important only to some devices using isochronous dataflow transfers. Moreover, this rigid requirement often can increase the amount of logic required in the host controller and limit the bus throughout.
USB uses a suspended state to conserve power, which is managed through the generation of the SOF packets. A USB device on the bus enters the suspended state after keeping an idle state on the bus for 3 ms. During multiple frames over which the host has no communications with the device, the SOF packets keep the device from entering the suspended state. To enter the suspended state, the host stops the generation of the SOF packets and the device will be idle. After 3, the device will enter the suspended state. Thus, one purpose of the SOF packets for USB devices utilizing bulk and/or interrupt transfers is to keep the devices from entering the suspended state. Unlike USB devices using isochronous transfers, USB devices using bulk and/or interrupt transfers do not need tight and rigid timing on the frame interval. For these devices, relaxation of the tight timing on the frame interval may reduce the amount of logic required to generate an SOF packet and increase the overall performance.
Accordingly, there exists a need for a USB host controller that can relax frame timing with respect to the generation of the SOF packets.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method for controlling SOF packet generation and capable of relaxing the frame timing of SOF packet generation sequences. In one aspect, the invention is a method of controlling packet generation in a bus through a host controller, wherein the host controller includes a timer that outputs a count signal at a predetermined time interval and a count expiration signal and the bus couples a host to a plurality of devices. The method includes performing the steps of producing a request for generating an SOF packet, determining if there is another transaction occurring in the bus, generating an SOF packet if there is not another transaction occurring in the bus, and delaying the generation of an SOF packet if there is another transaction occurring in the bus until the transaction is complete.
In another aspect, the invention is a method of controlling SOF packet generation in a bus through a host controller, wherein the host controller includes a timer that outputs a count signal at a predetermined time interval and a count expiration signal and the bus couples a host to a plurality of devices. The method includes performing the steps of writing an SOF enable bit having a first value or a second value, determining the value of the SOF enable bit, receiving a count expiration signal, producing a request for generating an SOF packet when the value of the SOF enable bit is the first value, and generating an SOF packet. The first value can be chosen as one (“1”), and the second value can be chosen as zero (“0”).
In yet another aspect, the invention is a host controller apparatus for use with a bus and a host, wherein the bus couples the host to a plurality of devices. The host controller has a microprocessor, a timer, and an SOF packet generator coupled to the microprocessor and the timer. The SOF packet generator can perform the steps of producing a request for generating an SOF packet, determining if there is another transaction occurring in the bus, generating an SOF packet if there is not another transaction occurring in the bus, and delaying the generation of an SOF packet if there is another transaction occurring in the bus until the transaction is complete. The microprocessor writes an SOF enable bit having a first value or second value and the timer outputs a count signal at a predetermined time interval and a count expiration signal to the SOF packet generator. The SOF packet generator produces the request for generating an SOF packet when the SOF enable bit has the first value, and maintains current count from the timer for at least one device in a suspended state when the SOF enable bit has the second value. In one embodiment of the invention, the first value is chosen as one (“1”), and the second value is chosen as zero (“0”).
These and other aspects will become apparent from the following description of the preferred embodiment taken in conjunction with the following drawings, although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
FIG. 1 is an overall block diagram of a hardware/software architecture of a USB host controller according to one embodiment of the invention.
FIG. 2 is a flow chart describing a method employed in one embodiment of the invention.
FIG. 3 is a flow chart describing a method employed in one embodiment of the invention.
FIGS. 4 and 5 illustrate two examples of frame time usage related to the USB host controller of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The invention is now described in detail. Referring to the drawings, like numbers indicate like parts throughout the views. As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
FIG. 1 is an overall block diagram of a hardware/software architecture of a USB host controller that can be used in digital devices such as a printer or a printing system including a copy machine, a fax machine, etc., according to one embodiment of the invention. As shown in FIG. 1, the invention is a USB host controller 1 that includes an SOF packet generator 100 connected to a microprocessor 3 and to a host timer 5 .
The SOF packet generator 100 includes an SOF packet control register 102 that has logic circuitry. SOF packet control register 102 is controllable by the microprocessor 3 through a microprocessor interface 104 . Additionally, the SOF packet control register 102 receives outputs from the host timer 5 . The SOF packet generator 100 also includes an SOF packet control state machine 106 that is coupled to the SOF packet control register 102 , and an SOF packet generation logic 108 that is coupled to the SOF packet control state machine 106 . The SOF packet control state machine 106 communicates with the SOF packet control register 102 and the SOF packet generation logic 108 . The SOF packet control state machine 106 can, among other functionality, receive, analyze, generate and transmit command signals from/to the SOF packet control register 102 and the SOF packet generation logic 108 .
The host timer 5 is a constant interval timer. In other words, the host timer 5 is a free running timer that outputs a pulse as a count at a predetermined time interval, which is chosen as 1 ms per the USB specification for the embodiment shown in FIG. 1 . Alternatively, a time interval other than 1 ms time interval may be used to practice the present invention. The host timer 5 also outputs a current count so that the count can be read by the microprocessor 3 to determine the frame time.
Through the microprocessor interface 104 , which includes logic circuitry necessary to interface or handshake with a microprocessor, the microprocessor 3 can control reads of and writes to registers coupled to the USB host controller 1 including the SOF packet control register 102 . The SOF packet control register 102 has one bit, an SOF enable bit, which can be written or set by the microprocessor 3 to have a first value or a second value. For the embodiment shown in FIG. 1, the first value of the SOF enable bit is chosen as one (“1”) and the second value of the SOF enable bit is chosen as zero (“0”). Alternatively, the SOF enable bit can take other sets of values representing either of states yes-no, on-off, etc.
When the SOF enable bit is set to “1”, the SOF packet control register 102 produces a request for generating an SOF packet to keep devices on the USB in normal operation mode. In other words, the SOF packet control register 102 prevents devices on the USB from entering a suspended state and thus impairing transaction efficiency. The request for generating an SOF packet is then output to the SOF packet control state machine 106 . Additionally, the SOF packet control register 102 holds the request for generating an SOF packet until an SOF end signal is received from the SOF packet control state machine 106 as discussed in more detail below.
On the other hand, when the SOF enable bit is set to “0”, the SOF packet control register 102 produces no request for generating an SOF packet. This effectively stops the generation of an SOF packet and lets devices on the USB enter a suspended state, which may be desirable when no device on the USB is active, or at the choice of the microprocessor 3 . The SOF packet control register 102 maintains the current count from the timer 5 , which the microprocessor 3 can access on a read-only basis. Thus, the host controller 1 is able to effectively manage the suspended states of peripheral devices on the USB by utilizing the SOF enable bit in connection with the SOF packet control register 102 .
Upon receiving a request for generating an SOF packet from the SOF packet control register 102 , the SOF packet control state machine 106 determines if there is another transaction currently occurring or underway in the bus. If no, the SOF packet control state machine 106 signals the SOF packet generation logic 108 to start an SOF packet. When the SOF packet generation logic 108 generates the SOF packet, the SOF packet control state machine 106 also outputs an SOF end signal to the SOF packet control register 102 , which, upon receiving the SOF end signal, generates a signal to notify the microprocessor 3 that the SOF has occurred. In one embodiment, the signal to the microprocessor 3 is in the form of an interrupt request that is maskable under software control.
On the other hand, if there is another transaction currently occurring in the bus, the SOF packet control state machine 106 waits until the transaction is complete to signal the SOF packet generation logic 108 to start an SOF packet. When the SOF packet is sent, the SOF packet control state machine 106 also outputs an SOF end signal to the SOF packet control register 102 indicating that the SOF packet has been sent.
Thus, the frame timing with respect to the generation of SOF packets can be “relaxed” by the SOF packet control state machine 106 delaying the start of the next SOF packet until a transaction in progress (“TIP”) is complete, as the generation of the next SOF packet may not coincide with the next 1 ms interval. This effectively extends the time window during which a device may drive the bus to perform a transaction and can improve the productivity of the bus.
FIGS. 4 and 5 illustrate what is meant by relaxing the frame timing according to the present invention. In FIG. 4, frame N, where N is an integer, starts with an SOF packet in time period 410 and ends with the EOF interval in time period 412 , and next frame N+1 starts with another SOF packet in time period 420 and ends with the EOF interval in time period 422 . In reference to time, the EOF interval for the frame N starts at t 1 and ends at t 2 , and the generation of the SOF packet for the frame N+1 starts at t 2 . Likewise, frame N+1 starts with an SOF packet in time period 430 at t 4 .
Referring now to FIG. 5, the present invention allows data transmission during the normal EOF interval. Therefore, there are no EOF intervals represented in FIG. 5 . However, a TIP is depicted in time period 512 during the normal EOF interval. If the TIP is on the bus when a scheduled SOF packet time period arrives, the generation of the SOF packet for the N+1 frame does not start at t 2 , but is delayed to a time t 3 when the TIP on the bus is complete. Thus, the time framing for the generation of the SOF packet of the N+1 frame is “relaxed” to t 3 , and the TIP is given a larger time window to complete. The width defined by (t 3 -t 1 ) is the additional time that the TIP has to complete, utilizing both the EOF time period and a small amount of time from the N+1 frame.
Because the operation of the timer 5 is independent of the start of the frame, the average frame interval will still be 1.0 ms over time while some frames are relaxed. One frame may be stretched by a transaction occurring at the end of the frame, and the next frame will be shortened if bus activity allows. This is illustrated in FIGS. 4 and 5. While the SOF packet in time period 520 for the N+1 frame in FIG. 5 was “relaxed” until t 3 , the SOF packet for the N+2 frame in FIG. 5 starts at t 4 in time period 530 . The corresponding time period 430 for the SOF packet in FIG. 4 also starts at t 4 , thus maintaining the 1.0 ms average frame interval over time. Relaxing the SOF timing effectively utilizes the end-of-frame interval to increase the through put on the bus and to decrease the host controller's logic. Thus, the present invention can be utilized in digital devices that use bulk and interrupt transactions, which, unlike isochronous devices, do not require precise timing of the USB frame interval to improve the efficiency and productivity of the bus.
Furthermore, if it is needed to prevent the frame interval from varying, the microprocessor 3 can read the timer 5 's count to determine the remaining frame time. If the frame time is insufficient for the next pending transaction, the microprocessor 3 can hold the execution of the transaction until after the timer 5 's count has wrapped around. This will delay the transaction to the next frame and thus prevent a shift in the SOF timing.
FIG. 2 is a flow chart illustrating how the host controller 1 makes a request for generating an SOF packet starting at step 210 . Specifically, in step 212 , the microprocessor 3 through microprocessor interface 104 produces an SOF enable bit having value either “1” or “0” In step 214 , it is determined whether the value of the SOF enable is one (“1”). If no, at step 226 , the SOF packet control register 102 prohibits the generation of the request for generating an SOF packet, and thus no SOF packet is generated in response. At step 228 , devices on the USB enter or remain in the suspended state. Then control returns to step 210 to proceed with the next cycle.
Still referring to FIG. 2, if it is determined that the value of the SOF enable is one (“1”), at step 216 , it is determined whether the SOF packet control register 102 receives a count expiration signal from the timer 5 . If not, control goes to step 214 to continue as discussed above, i.e., no SOF packet is generated in response. If yes, however, at step 218 , a request for generating an SOF packet is produced, and at step 220 , the request is output (to the SOF packet control state machine 106 ) for further processing.
FIG. 3 is a flow chart illustrating how an SOF packet is generated according to one embodiment of the present invention. Specifically, at step 310 , a request for generating an SOF packet is received. At step 312 , it is determined if there is another transaction occurring in the bus. If there is not, at step 324 , an SOF packet is generated immediately. Referring to FIG. 4, it means that an SOF packet is generated at t 2 .
If in step 312 it is determined that there is another transaction (i.e., a TIP) occurring in the bus, then in step 314 the generation of the SOF packet is delayed until the transaction is complete. Referring to FIG. 5, it means that the SOF packet 520 is not generated at t 2 and will be delayed to t 3 . After the transaction is complete, control goes to step 324 and an SOF packet is then generated. Again referring to FIG. 5, it means that the SOF packet is generated at t 3 after the transaction is complete.
The above described embodiments are given as illustrative examples only. It will be readily appreciated that many deviations may be made from the specific embodiment disclosed in this specification without departing from the invention. Accordingly, the scope of the invention is to be determined by the claims below rather than being limited to the specifically described embodiment above.
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An apparatus and method for controlling packet generation in a bus that couples a host to a plurality of devices. The apparatus includes a host controller for use with the bus and the host. The host controller has an SOF packet generator capable of delaying the generation of an SOF packet if there is another transaction occurring in the bus until the transaction is complete, thereby to relax the frame timing of SOF packet generation sequences.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application of International Application PCT/JP2011/063271, filed on Jun. 9, 2011 and designating the U.S., the entire contents of which are incorporated herein by reference.
FIELD
[0002] The present invention relates to a drop determining device and a drop determining method.
BACKGROUND
[0003] Conventionally, there has been a technique for detecting the acceleration of an object in movement and determining the state of the object based on the detection result, using an acceleration sensor. This acceleration sensor realizing the technique includes a low range sensor suitable for detection of low acceleration and a high range sensor suitable for detection of high acceleration. The low range acceleration sensor has a high resolution in detection of acceleration about ±5 G or lower, and is thus suitable for determining some state, such as walking involving the acceleration of 0.5 to 2.0 G. It is used, for example, for a pedometer for mobile terminals. On the other hand, the high range acceleration sensor has a high resolution in detection of acceleration about ±70 G, and is thus suitable for determining some state, such as dropping involving an impact of several ten to 100 G. In recent years, there has been proposed a mobile terminal which has a plurality of acceleration sensors with different ranges and switches between these sensors in accordance with the aspect.
Patent Literature 1: Japanese Laid-open Patent Publication No. 2008-175771
[0005] However, the acceleration range that can accurately be detected by the acceleration sensor is restricted for each sensor, and there does not exist acceleration sensor that has a high resolution in all ranges. For example, because the dropping of a mobile terminal involves a strong impact thereon, the low range acceleration sensor does not detect the accurate acceleration. In view of this circumstance, it may be considered that the drop determination may be performed by the high range acceleration sensor. However, it is difficult to adopt the high range acceleration sensor into the application requiring acceleration detection with a high resolution in a low range. That is, if a high range acceleration sensor is installed in a mobile terminal, a problem is the difficulty of realizing the function of the application, such as the pedometer. As described above, in combination of both of the low range and high range acceleration sensors, acceleration detection is possible in a wide range. However, installation of a plurality of acceleration sensors into the mobile terminal may be a factor of hindering the miniaturization or weight reduction.
SUMMARY
[0006] To solve the above problem and attain the object, a drop determining device disclosed in this application, according to an aspect, includes a detecting unit, a calculating unit, and a determining unit. The detecting unit detects acceleration within a predetermined range. The calculating unit calculates acceleration outside the predetermined range, using the acceleration detected by the detecting unit. The determining unit determines whether drop has occurred, using the acceleration calculated by the calculating unit.
[0007] The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
[0008] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is a diagram illustrating a functional configuration of a mobile terminal;
[0010] FIG. 2 is a diagram illustrating a data storage example in an acceleration conversion table, in a first embodiment;
[0011] FIG. 3 is a diagram illustrating a hardware configuration of the mobile terminal;
[0012] FIG. 4 is a flowchart for explaining an operation of the mobile terminal in the first embodiment;
[0013] FIG. 5 is a diagram for explaining a procedure for calculating the impact time and the acceleration at impact, in the first embodiment;
[0014] FIG. 6 is a diagram illustrating a data storage example in the acceleration conversion table, in a second embodiment;
[0015] FIG. 7 is a flowchart for explaining an operation of a mobile terminal, in the second embodiment;
[0016] FIG. 8 is a diagram for explaining a procedure for calculating the range of the impact time and the acceleration at impact, in the second embodiment; and
[0017] FIG. 9 is a diagram illustrating a computer that executes a drop determining program.
DESCRIPTION OF EMBODIMENTS
[0018] Descriptions will now specifically be made to embodiments of a drop determining device and a drop determining method, as disclosed in the present application, with reference to the drawings. The embodiments are not intended to limit the drop determining device and drop determining method disclosed in the present application.
First Embodiment
[0019] Descriptions will now be made to a configuration of a mobile terminal according to the embodiment, in a drop determining device disclosed in the present application. FIG. 1 is a diagram illustrating a functional configuration of a mobile terminal 10 according to this embodiment. As illustrated in FIG. 1 , the mobile terminal 10 has a sensor unit 11 , a sampling processing unit 12 , an impact calculating unit 13 , and an application processing unit 14 . Each of these constituent parts are connected with each other, for enabling input/output of signals or data unidirectionally or bidirectionally.
[0020] The sensor unit 11 is a low range acceleration sensor unit whose range value is set to ±4 G. That is, the sensor unit 11 can detect (measure) the acceleration up to +4 G as the upper limit value, and can detect (measure) the acceleration down to −4 G as the lower limit value. The sensor unit 11 is a well-known and commonly-used sensor, and thus will not specifically be described. The sensor unit 11 is a triaxial acceleration sensor which detects acceleration in triaxial directions which are orthogonal to each other. The acceleration in the X-axis direction is a displacement value in accordance with the movement in the crosswise direction, in the exercise (walking or dropping) involving the acceleration. That is, the acceleration in the X-axis direction is the amount of movement in the crosswise direction based on the installation position of the sensor unit 11 at a predetermined point of time. The acceleration will become a positive value for an amount of movement in the left direction, and will become a negative value for an amount of movement in the right direction. The acceleration in the Y-axis direction is a displacement value in accordance with the movement in the vertical direction, in the exercise involving the acceleration. That is, the acceleration in the Y-axis direction is the amount of movement in the vertical direction based on the installation position of the sensor unit 11 at a predetermined point of time. The acceleration will become a positive value for an amount of movement in the upper direction, and will become a negative value for an amount of movement in the lower direction. The acceleration in the Z-axis direction is a displacement value in accordance with the movement in the front-back direction, in the exercise involving the acceleration. That is, the acceleration in the Z-axis direction is the amount of movement in the front-back direction based on the installation position of the sensor unit 11 at a predetermined point of time. The acceleration will become a positive value for an amount of movement in the front direction, and will become a negative value for an amount of movement in the back direction.
[0021] The sampling processing unit 12 periodically samples a value of the acceleration detected by the sensor unit 11 , and outputs the value to the impact calculating unit 13 . The sampling period is preferably a short period of, for example, 1 ms, and more preferably, 0.1 ms, from the perspective of performing acceleration detection in high range and also impact calculation with high accuracy.
[0022] The impact calculating unit 13 calculates the out-of-range acceleration of higher than 4 G, using the acceleration input from the sampling processing unit 12 , after detected by the sensor unit 11 . That is, the impact calculating unit 13 calculates the out-of-range acceleration, using the time at which the acceleration detected by the sensor unit 11 exceeds 4 G, the time at which the corresponding acceleration returns into the range of 4 G or lower, the slope of the acceleration before the exceeding time, and the slope of the acceleration after the returned time. The impact calculating unit 13 outputs the value of the calculated acceleration as an estimated value of the acceleration at impact, to the application processing unit 14 .
[0023] During activation of the drop determining application, the application processing unit 14 converts the value (estimated value) of the acceleration at impact, calculated by the impact calculating unit 13 , into an actual measurement value, and compares the value with a threshold value. If the converted acceleration is equal to the threshold value or higher, it is determined that there is a drop. Then, the application processing unit 14 displays this drop determination result.
[0024] The application processing unit 14 has an acceleration conversion table 141 a . FIG. 2 is a diagram illustrating a data storage example in the acceleration conversion table 141 a for converting the acceleration (estimated value) at impact into an actual measurement value, in the first embodiment. As illustrated in FIG. 2 , the acceleration conversion table 141 a stores the acceleration at impact that is calculated by the impact calculating unit 13 as an “M estimated value” and the acceleration at impact that is measured in advance by a high range acceleration sensor as an “actual measurement value”, in association with each other. For example, when the M estimated value is calculated to be “5.00 G”, a value “5.50 G” is referred for a comparison with the threshold value, because the actual acceleration value is set in advance to “5.50 G”. Similarly, when the M estimated value is calculated to be “80.20 G”, this value is referred for determination as to whether the drop has occurred, because the actual acceleration value set in advance is “80.68 G”. As described above, the acceleration at impact that is calculated by the impact calculating unit 13 as the M estimated value is corrected into an actual measurement value by the application processing unit 14 .
[0025] The correspondence relationship between the M estimated value and the actual measurement value set in the acceleration conversion table 141 a can be updated based on the actually measured acceleration which has been measured at impact (dropping or throwing) of the mobile terminal 10 . That is, the application processing unit 14 appropriately updates the above-described correspondence relationship in the acceleration conversion table 141 a , in accordance with the impact characteristics of the sensor unit 11 or the calculation accuracy of the M estimated value, and always maintains up-to-date status. Thus, the application processing unit 14 can perform drop determination based on the accurate acceleration value which is pretty close to the actual value, with reference to the acceleration conversion table 141 a . Therefore, the mobile terminal 10 can acquire a drop determination result with a high level of accuracy, resulting in increase in the reliability of the mobile terminal 10 .
[0026] The above-described mobile terminal 10 is physically realized with, for example, a mobile phone. FIG. 3 is a diagram illustrating a hardware configuration of a mobile phone as the mobile terminal 10 . As illustrated in FIG. 3 , the mobile terminal 10 physically has a CPU (Central Processing Unit) 10 a , an acceleration sensor 10 b , a memory 10 c , a display unit 10 d , and a wireless unit 10 e having an antenna A. The sensor unit 11 is realized with the acceleration sensor 10 b , as described above. The sampling processing unit 12 , the impact calculating unit 13 , and the application processing unit 14 are realized with an integrated circuit, such as the CPU 10 a . The range value, the threshold value of the drop determination, the sampling value of the acceleration, and the acceleration conversion table 141 a are kept in the memory 10 c , such as RAM (Random Access Memory), a ROM (Read Only Memory), and a flash memory. The impact calculation result is displayed on the display unit 10 d , such as an LCD (Liquid Crystal Display).
[0027] An operation of the mobile terminal 10 will now be described. The following operational descriptions will be made on the assumption that a user drops the mobile terminal 10 in the acceleration range of ±4 G on the floor surface for some reason.
[0028] FIG. 4 is a flowchart for explaining an operation of the mobile terminal 10 . When the user activates a drop determining application of the mobile terminal 10 (S 1 ), the sampling processing unit 12 acquires an acceleration value in the triaxial directions input from the sensor unit 11 at a predetermined period, to start sampling of the acceleration (S 2 ).
[0029] The impact calculating unit 13 always keeps the acceleration values which have been sampled at a one time-period prior to and two time-periods prior to the most recent sampling time, as sampling values (S 3 ). While the impact calculating unit 13 keeps the sampling value, it also monitors whether the latest sampling value has exceeded the range (±4 G) of the sensor unit 11 (S 4 ). As a result of the monitoring, when the sampling value has exceeded the range of the sensor unit 11 (S 4 ; Yes), it moves to the procedure of S 5 . Sampling values a 1 and a 2 corresponding to the two time periods before the excess of the range are not deleted even if the next sampling value would be acquired, and are continuously kept in the memory 10 c.
[0030] In S 5 , after the excess of the range, the impact calculating unit 13 keeps a sampling value b 2 right after returned into the range and a sampling value b 3 at one time period after that. Further, the impact calculating unit 13 keeps a time t 1 of the overrange and a returned time t 2 into the range, into the memory 10 c (S 6 ). The time t 1 can be calculated as a time at which the sensor unit 11 stops sampling the acceleration. The time t 2 can be calculated as a time at which the sensor unit 11 restarts sampling the acceleration, and can also be calculated by adding an obtained value of “the number of samples during the times t 1 t 2 *the sampling period” to the time t 1 .
[0031] As a result of the above monitoring, while the sampling value remain within the range of the sensor unit 11 (S 4 ; No), the mobile terminal 10 continues to keep the sampling values corresponding to the most recent two time periods by the impact calculating unit 13 (S 3 ). The kept sampling values at this time remain in data corresponding to two time periods. Thus, the space of the memory 10 c is not wasted, even if the sampling process is executed for a long time upon activation of the drop determining application.
[0032] In S 7 , the impact calculating unit 13 calculates a slope S 1 of the acceleration before the overrange. In S 3 , the impact calculating unit 13 keeps the sampling values a 1 and a 2 right before the excess of the range. Thus, the slope S 1 can be calculated using the values and the sampling period, by |a 1 −a 2 |/c. Similarly, in S 8 , the impact calculating unit 13 calculates a slope S 2 of the acceleration after returned into the range. Because the impact calculating unit 13 , in S 5 , keeps the sampling values b 2 and b 3 right after returned into the range, the slope S 2 can be calculated using the values and the sampling period, by |b 2 −b 3 |/c. These calculation results are kept in the memory 10 c.
[0033] The impact calculating unit 13 calculates a time t c at which the mobile terminal 10 gets an impact and the acceleration M at that time, using the times t 1 and t 2 kept in S 6 and the slopes S 1 and S 2 kept in S 7 and S 8 (S 9 ).
[0034] Descriptions will now specifically be made to a method for calculating the impact time t c and the acceleration M at impact, with reference to FIG. 5 . In FIG. 5 , the time t [ms] is assigned to the x axis, while the acceleration [G] is assigned to the y axis. A time t 0 is the time at which the mobile terminal 10 is dropped and comes in contact with the floor surface. A time t 1 is a time at which the acceleration detected by the sensor unit 11 exceeds +4 G as the upper value of the range, while a time t 2 is a time at which the detected acceleration has returned into the range again. Further, the sampling period is set to 1 [ms], the slope (the slope between circles a 1 and a 2 in FIG. 5 ) kept in S 7 is set as S 1 , and the slope (the slope between triangles b 2 and b 3 in FIG. 5 ) kept in S 8 is set as S 2 . The circle a 3 is a sampling value right after (out of range) the acceleration detected by the sensor unit 11 has exceeded the upper limit of the range. Since this acceleration is not in fact detected, it is represented by a broken line, to distinguish from the circles a 1 and a 2 representing the sampling values of the detected acceleration. Similarly, the triangle b 1 is a sampling value right before (out of range) the acceleration detected by the sensor unit 11 returns into the range. Since this acceleration is not in fact detected, it is represented by a broken line to distinguish from the triangles b 2 and b 3 representing the sampling values of the detected acceleration.
[0035] Under the above-described conditions, the impact time as a calculation target in S 9 is set as t c , the relationship of t c −t 1 :t 2 −t c =S 2 :S 1 is made. Thus, t c can be calculated using the following equation (1).
[0000] Time at impact t c =( S 1 t 1 +S 2 t 2 )/( S 1 +S 2 ) (1)
[0036] Under the above-described condition, when the acceleration at impact as a calculation target in S 9 is set as M, the relationships of M=S 1 t c +b and 4=S 1 t 1 +b (b is a constant) are made. Thus, the acceleration M of t c can be calculated using the following equation (2).
[0000] Acceleration at impact M=S 1 S 2 ( t 2 −t 2 )/( S 1 +S 2 )+4 (2)
[0037] That is, the impact calculating unit 13 obtains two-dimensional coordinates of an intersection point D of a straight line B passing through the circles a 1 and a 2 and a straight line C passing through the triangles b 2 and b 3 . The impact calculating unit 13 assumes the x coordinate value as the time at impact t c , and also assumes the y coordinate as the acceleration at impact M.
[0038] In S 10 , the application processing unit 14 converts the acceleration M calculated by the impact calculating unit 13 in S 9 into an actual measurement value. This conversion process is executed with reference to the above-described acceleration conversion table 141 a . The acceleration M is not a value detected actually by the sensor unit 11 , but is a value (estimated value) calculated using the equation just based on the actual measurement values. Thus, there is a possibility that the acceleration M does not coincide with the actual acceleration value. The application processing unit 14 performs correction to convert the estimated value into an actual measurement value, for the acceleration value for use in drop determination to approximate to the actual acceleration value, based on the correspondence relationship between the estimated value and the actual measurement value as set in the acceleration conversion table 141 a . For example, when the acceleration at impact calculated by the impact calculating unit 13 in S 9 is “80.00”, it is converted into “80.46” (see FIG. 2 ).
[0039] In S 11 , the application processing unit 14 determines whether the mobile terminal 10 has been dropped, based on the acceleration at impact (actual measurement value of FIG. 2 ) after the conversion in S 10 and a threshold value T 1 illustrated in FIG. 5 . That is, the application processing unit 14 compares the magnitude relationship between the acceleration at impact M and a preset threshold value T 1 . When the acceleration at impact M≧threshold value T 1 , it is determined that the drop has occurred. On the contrary, when the acceleration at impact M<the threshold value T 1 , the application processing unit 14 determines that the drop has not occurred. At the time of drop, since the acceleration of several ten to 100 G occurs on the mobile terminal 10 in accordance with the material of the contact surface, the threshold value T 1 is set, for example, to 20 G. Note, however, that this set value can adequately be changed, in accordance with the specifications of the mobile terminal 10 or the calculation accuracy of the estimated value.
[0040] When it is determined that the drop has occurred in S 11 , the impact time t c calculated in S 9 as “drop time” is recorded in the memory 10 c , together with information representing that the drop has occurred. At the same time, a message is displayed on the display unit 10 d , and represents, for example, “drop has occurred, about 10:20:35, 19, May”.
[0041] As described above, the mobile terminal 10 according to this embodiment has the sensor unit 11 , the impact calculating unit 13 , and the application processing unit 14 . The sensor unit 11 detects the acceleration within the above-described predetermined range. The impact calculating unit 13 calculates the acceleration outside the above-described predetermined range, using the acceleration detected by the sensor unit 11 . The application processing unit 14 determines the occurrence of the drop, using the above-described acceleration calculated by the impact calculating unit 13 . In more particular, the impact calculating unit 13 calculates the acceleration outside the above-described predetermined range, using the time t 1 , the time t 2 , the slope S 1 of the acceleration, and the slope S 2 of the acceleration. The time t 1 is the time at which the acceleration detected by the sensor unit 11 has exceeded the above-described predetermined range. The time t 2 is the time at which the acceleration has returned into the predetermined range. The slope S 1 is the slope of the acceleration before the time t 1 . The slope S 2 is the slope of the acceleration after the time t 2 . The application processing unit 14 determines the occurrence of the drop, based on whether the acceleration calculated by the impact calculating unit 13 is a predetermined value or higher.
[0042] The mobile terminal 10 according to this embodiment calculates the time of applied impact and the acceleration at that time, using the acceleration detected with a low range acceleration sensor. As a result, it is possible to determine the occurrence of the drop involving a high range impact, without installing a high range acceleration sensor. In other words, the mobile terminal 10 calculates the acceleration within a range that is unmeasurable by the low range acceleration sensor due to range insufficiency, using a predetermined equation. The mobile terminal 10 assumes an acceleration value outside the range, based on the result. The mobile terminal 10 can quickly discriminate when and how much impact the drop has occurred. Thus, if the mobile terminal 10 is one to record and display the discrimination result as historical information, the user can easily recognize the occurrence of the drop and its time. Not only the user, but also a third party, such as the communication enterprise (carrier) or manufacturer, can easily and quickly know the occurrence of the drop, by referring to the above-described historical information. Even if the mobile terminal 10 is damaged or is unusable due to the impact of drop, the third party can inform the user that it is caused by the drop, based on the drop time.
[0043] Specifically, the mobile terminal 10 according to this embodiment uses the slope right before the acceleration exceeds the range as the slope S 1 , of slopes of the acceleration before the time t 1 . The slope of the acceleration before the time t 1 reaches the upper limit value (4 G) of the range while increasing the accuracy, during the time since the mobile terminal 10 comes in contact with the floor surface until the acceleration exceeds the range, and resulting in the overrange. Therefore, the mobile terminal 10 uses the actual measurement value (the actual measurement value nearly outside the range as much as possible) of the acceleration right before the overrange, in calculation of the estimated acceleration, thereby enabling to calculate the acceleration with less error even outside the range. As a result, the mobile terminal 10 can estimate the acceleration with high accuracy. For the slope on the side of returning into the range, the mobile terminal 10 uses the slope right after the acceleration returns into the range as the slope S 2 , of slopes of the acceleration after the time t 2 . The slope of the acceleration after the time t 2 gets close to 0 [G], while decreasing the accuracy and reducing the acceleration value, after the mobile terminal 10 comes in contact with the floor surface, as time goes by. Therefore, the mobile terminal 10 uses the actual measurement value (the actual measurement value nearly outside the range as much as possible) of the acceleration right after returned into the range, in calculation of the estimated acceleration, thereby enabling to calculate the acceleration with less error even outside the range. As a result, the mobile terminal 10 can estimate the acceleration with high accuracy.
Second Embodiment
[0044] Descriptions will now be made to the mobile terminal according to a second embodiment. The second embodiment differs from the first embodiment, in the method for calculating the impact time and the acceleration at impact. That is, in the first embodiment, the mobile terminal 10 has obtained the impact time and the acceleration value at impact, using the intersection point of two straight lines. However, in the second embodiment, the impact time will be calculated first, and then the range of the acceleration values at the time is obtained.
[0045] The configuration of the mobile terminal according to the second embodiment is the same as that of the mobile terminal 10 of the first embodiment, except the data stored in the acceleration conversion table. Thus, the common constituent elements have the same reference numerals, and the entire configuration is not illustrated and the specific description is omitted. Hereinafter, an acceleration conversion table having a different form from that of the first embodiment will be described.
[0046] The application processing unit 14 in the second embodiment has an acceleration conversion table 141 b . FIG. 6 is a diagram illustrating a data storage example in the acceleration conversion table 141 b for converting the acceleration (estimated value) at impact into an actual measurement value. As illustrated in FIG. 6 , the acceleration conversion table 141 b stores the maximum acceleration at impact that is calculated by an impact calculating unit 13 , as an “M1 estimated value”, and stores also the minimum acceleration at impact as an “M2 estimated value”. Further, the acceleration conversion table 141 b has the acceleration at impact that has been measured in advance by a high range acceleration sensor as the “actual measurement value”, in association with these estimated values. For example, when the M1 estimated value is calculated to be “5.10 G”, and when this value is selected as the acceleration at impact, “5.59 G” is set as a corresponding actual measurement value. Thus, “5.59 G” is used for a comparison with a threshold value. Similarly, when the M2 estimated value is calculated to be “79.70 G”, and when this value is selected as the acceleration at impact, the actual measurement value set in advance is “80.57 G”. Thus, this value is used for determination as to whether the drop has occurred. As described above, the acceleration at impact (as the M1 estimated value or the M2 estimated value) calculated by the impact calculating unit 13 is corrected into an actual measurement value of the acceleration by the application processing unit 14 . Note that the M1 estimated value and the M2 estimated value corresponding to the actual measurement values and set in the acceleration conversion table 141 b can be appropriately updated, like the first embodiment.
[0047] Descriptions will now be made to an operation of a mobile terminal 10 in the second embodiment. The operation is also the same as the mobile terminal 10 in the first embodiment, except a process for calculating the impact time and the acceleration value at impact, and for converting a calculation result into an actual measurement value. Thus, the common steps have reference numerals having the common end, and will not be explained again. FIG. 7 is a flowchart for explaining an operation of the mobile terminal 10 in the second embodiment. The operation of the mobile terminal 10 according to the second embodiment is the same as that of the mobile terminal 10 according to the first embodiment, except the steps from T 9 to T 11 . Specifically, the procedures from S 1 to S 8 and S 11 of FIG. 4 in the first embodiment correspond to the procedures from T 1 to T 8 and T 12 of FIG. 7 in the second embodiment, respectively.
[0048] Descriptions will now be made to the procedures of T 9 to T 11 that are not included in the first embodiment, with reference to FIG. 7 and FIG. 8 .
[0049] In FIG. 8 , it is assumed that the time t [ms] is assigned to the x axis and the acceleration [G] is assigned the y axis, like the first embodiment. A time t 0 is the time at which the mobile terminal 10 is dropped and comes in contact with the floor surface. A time t 3 is the time at which the acceleration detected by the sensor unit 11 has exceeded +4 G as the upper limit value of the range, and a time t 4 is the time at which the detected acceleration has returned into the range again. Further, the sampling period is set to 1 [ms], the slope (the slope between circles a 4 and a 5 in FIG. 8 ) kept in T 7 is set as S 3 , and the slope (the slope between the triangles b 5 and b 6 in FIG. 8 ) kept in T 8 is set as S 4 . A circle t 6 is a sampling value right after (out of range) the acceleration detected by the sensor unit 11 has exceeded the upper limit value of the range. Because this acceleration is not in fact detected, it is represented by a broken line to distinguish from the circles a 4 and a 5 representing the sampling values of the detected acceleration. Similarly, the triangle b 4 is a sampling value right before (out of range) the acceleration detected by the sensor unit 11 returns into the range. Because this acceleration is not in fact detected, it is represented by a broken line to distinguish from the triangles b 5 and b 6 representing sampling values of the detected acceleration.
[0050] In FIG. 8 , a threshold value T 2 is set, and is compared with an actual measurement value in drop determination. However, this threshold value T 2 may be a different value from the threshold value T 1 in the first embodiment.
[0051] Back to FIG. 7 , in T 9 , the mobile terminal 10 calculates a time at impact t m . Because the time at impact t m is an intermediate point between the time t 3 and the time t 4 , the following equation (3) is satisfied.
[0000] Time at impact t m =( t 3 +t 4 )/2 (3)
[0052] In T 10 , the mobile terminal 10 calculates the maximum value and minimum value of the acceleration at the time of impact. Under the above-described condition, when the maximum acceleration at impact as a calculation target in T 10 is set as M1, the relationships of M1=S 3 t m +b and 4=S 3 t 3 +b (b is a constant) are made. Thus, the maximum acceleration M1 at the time t m can be calculated using the following equation (4).
[0000] Maximum acceleration at impact M 1 =S 3 ( t 3 +t 4 )/2+4 −S 3 t 3 =S 3 ( t 4 −t 3 )/2+4 (4)
[0053] Similarly, under the above-described condition, when the minimum acceleration at impact as a calculation target in T 10 is set as M2, the relationships of M2=S 4 t m +b and 4=S 4 t 4 +b (b is a constant) are made. Thus, the minimum acceleration M2 at the time t m can be calculated using the following equation (5).
[0000] Minimum acceleration at impact M 2 =S 4 ( t 3 +t 4 )/2+4 −S 4 t 4 =S 4 ( t 3 −t 4 )/2+4 (5)
[0054] That is, the impact calculating unit 13 obtains two-dimensional coordinates of an intersection point H of a straight line E passing through the circles a 4 and a 5 and a straight line G representing the time t=t m , estimates the x coordinate value as the impact time t m , and estimates the y coordinate value as the upper limit value M1 within the range of the acceleration. Similarly, the impact calculating unit 13 obtains two-dimensional coordinates of an intersection point I of a straight line F passing through the triangles b 5 and b 6 and the above-described straight line G, estimates the x coordinate value as the impact time t m , and estimates the y coordinate value as the lower limit value M2 within the range of the acceleration.
[0055] In T 11 , the application processing unit 14 converts the acceleration calculated by the impact calculating unit 13 in T 10 into an actual measurement value. This conversion process is executed with reference to the above-described acceleration conversion table 141 b . The conversion of the estimated value into the actual measurement value may be performed for both of the maximum acceleration M1 and the minimum acceleration M2. However, from the perspective of enhancing the processing efficiency, the application processing unit 14 preferably performs the conversion into the actual measurement value, after calculating one value as an estimated value of a conversion target. For example, when the maximum acceleration at impact that is calculated by the impact calculating unit 13 in T 10 is “5.10”, this estimated value is converted into an actual measurement value of “5.59”. When the minimum acceleration is “79.80”, the value is converted into an actual measurement value of “80.68” (see FIG. 6 ).
[0056] As described above, the mobile terminal 10 according to the second embodiment has the sensor unit 11 , the impact calculating unit 13 , and the application processing unit 14 . The sensor unit 11 detects the acceleration within the above-described predetermined range. The impact calculating unit 13 calculates the acceleration outside the above-described predetermined range, using the acceleration detected by the sensor unit 11 . The application processing unit 14 determines whether the drop has occurred, using the acceleration calculated by the impact calculating unit 13 . In more particular, the impact calculating unit 13 calculates the maximum value and minimum value of the acceleration outside the above-described predetermined range, using the time t 3 , the time t 4 , the slope S 3 of the acceleration, and the slope S 4 of the acceleration. The time t 3 is the time at which the acceleration detected by the sensor unit 11 has exceeded the above-described predetermined range. The time t 4 is the time at which the above-described acceleration returns into the predetermined range. The slope S 3 is the slope of the acceleration before the time t 3 . The slope S 4 is the slope of the acceleration after the time t 4 . The application processing unit 14 determines the occurrence of the drop, based on whether the acceleration calculated by the impact calculating unit 13 is a predetermined value or higher.
[0057] That is, the mobile terminal 10 according to the second embodiment calculates a possible range of the acceleration at impact, and further calculates the acceleration to be converted into an actual measurement value from the acceleration values within the range, as an estimated value. Thus, the acceleration at impact is estimated as a value between the upper limit value M1 and the lower limit value M2 of the calculated acceleration. There are, for example, techniques for the application processing unit 14 to select or calculate either one value within the range. The application processing unit 14 selects the M1 estimated value as the maximum value of the acceleration, as a target estimated value to be converted into an actual measurement value. As a result, there is a high possibility that “actual measurement value threshold value”. Thus, in the mobile terminal 10 , it is possible to enhance the probability of determining that the drop has occurred. On the contrary, the application processing unit 14 selects the M2 estimated value as the minimum value of the acceleration as a target estimated value to be converted into an actual measurement value. Thus, there is a rigid rule for determining the occurrence of the drop, and relatively decreasing the possibility that “actual measurement value≧threshold value”. This results in restraining the percentage of determining the occurrence of the drop, in the mobile terminal 10 , and also increasing the probability of determining that the drop has not occurred.
[0058] Alternatively, the application processing unit 14 calculates an intermediate value of the M1 estimated value and the M2 estimated value, and may set the calculation result as an estimated value. The mobile terminal 10 can set the average estimated value at impact, and can use a non-biased actual measurement value as a comparison target with a threshold value, for determining whether the drop has occurred. The application processing unit 14 may set a line segment with both ends on the M1 estimated value and the M2 estimated value, and set a predetermined ratio value from the M1 estimated value as an estimated value. For example, when the predetermined ratio is 1/4, the acceleration value close to the side of the M1 estimated value will be the estimated value, and the condition for determining the drop will be mild. This causes easy determination that the drop has occurred. When the above-described predetermined ratio is set to 3/4, the acceleration value close to the side of the M2 estimated value will be the estimated value, and the condition for determining the occurrence of the drop will be rigid. This causes uneasy determination that the drop has occurred.
[0059] In FIG. 8 , the descriptions have been made to the example in which the side (straight line E) exceeding the range has the acceleration maximum value, and the side (straight line F) returning into the range has the acceleration minimum value. On the contrary, the straight line E may have the acceleration minimum value, and the straight line F may have the acceleration maximum value, depending on the slope S 3 before the exceeding of the range or the slope S 4 after returning into the range. To correspond to this case, the application processing unit 14 may set the acceleration value close to the estimated value on the side exceeding the range, as an estimated value. Specifically, when the estimated value on the side exceeding the range is the maximum estimated value M1, the application processing unit 14 sets the maximum estimated value M1 or the acceleration value at a predetermined ratio (for example, 0.1 to 0.4) from the maximum estimated value M1, as a target estimated value to be converted into an actual measurement value. On the other hand, when the estimated value on the side exceeding the range is the minimum estimated value M2, the application processing unit 14 sets the minimum estimated value M2 or the acceleration value at a predetermined ratio (for example, 0.1 to 0.4) from the minimum estimated value M2, as a target estimated value to be converted into an actual measurement value. As a result, the acceleration value which approximates to the estimated value on the side of the overrange is preferentially used as an estimated value. Thus, the mobile terminal 10 can always use the estimated value closest to the moment at which it comes in contact with the floor surface, for the conversion into an actual measurement value. This results in improving the estimation accuracy of the acceleration at the time of contact with the floor surface (at impact) and the accuracy of drop determination.
[0060] In this embodiment, the impact time t m is an intermediate point of the time t 3 and the time t 4 . However, not limited to this, the application processing unit 14 may set a line segment having both ends on the time t 3 and the time t 4 , and may set the time at a predetermined ratio (for example, 0.1 to 0.4) from the time t 3 as the impact time t m . As a result, the acceleration value at the time close to the time of exceeding the range is preferentially used as an estimated value. Therefore, the mobile terminal 10 can always use the estimated value closest to the moment that it comes in contact with the floor surface, for the conversion into an actual measurement value. This results in improving the estimation accuracy of the acceleration at the time of contact with the floor surface (at impact) and the accuracy of drop determination.
[0061] The times t 1 and t 2 in the first embodiment and the times t 3 and t 4 in this embodiment are relative times based on the time t o at the contact time. Because the mobile terminal 10 has a clock function, it can specify the actual impact time, in cooperation with this function. Therefore, the user or third party can accurately and easily know the time at which the mobile terminal 10 has been dropped, with reference to this time.
[Drop Determining Program]
[0062] These processes described in the above embodiments can be realized by controlling a computer to execute a prepared program. Descriptions will herein be made to an example of a computer executing a drop determining program having the same function as that of the mobile terminal 10 illustrated in FIG. 1 .
[0063] FIG. 9 is a diagram illustrating a computer for executing a drop determining program. As illustrated in FIG. 9 , a computer 100 has a CPU 110 , an input unit 120 , a monitor 130 , a voice input/output unit 140 , a wireless communication unit 150 , and an acceleration sensor 160 . Further, the computer 100 has a data memory unit, such as a RAM 170 and a hard disk unit 180 , and these are connected with each other through a bus 190 . The CPU 110 executes various arithmetic processes. The input unit 120 accepts data input from the user. The monitor 130 displays various kinds of information. The voice input/output unit 140 inputs/outputs voice. The wireless communication unit 150 transmits and receives data to and from another computer through wireless communication. The acceleration sensor 160 detects the acceleration in triaxial directions. The RAM 170 temporarily stores various kinds of information.
[0064] The hard disk unit 180 stores a drop determining program 181 having the same function as that of the CPU 10 a illustrated in FIG. 3 . The hard disk unit 180 stores a drop determining process relevant data 182 and a determination historical file 183 , corresponding to various data (range value, threshold value for drop determination, and sampling value of acceleration) stored in the memory 10 c illustrated in FIG. 3 .
[0065] The CPU 110 reads the drop determining program 181 from the hard disk unit 180 and expands it into the RAM 170 . As a result, the drop determining program 181 functions as a drop determining process 171 . The drop determining process 171 expands the information read from the drop determining process relevant data 182 into an area allocated to itself on the RAM 170 , and executes various data processes based on the expanded data. The drop determining process 171 outputs predetermined information to the determination historical file 183 .
[0066] The above-described drop determining program 181 is not necessarily stored in the hard disk unit 180 . This program stored on a recording medium, such as a CD-ROM, may be read and executed by the computer 100 . The program may be stored in another computer (or server) connected to the computer 100 through a public line, the Internet, a LAN (Local Area Network), a WAN (Wide Area Network). In this case, the computer 100 reads and executes the program therefrom.
[0067] In each of the above-described embodiments, the mobile terminal 10 is to correct the calculation result of the acceleration at impact into an actual measurement value. However, when the sampling period is a predetermined value (for example, 0.1 ms) or lower, the impact calculating unit 13 can calculate the acceleration estimated value at impact with high accuracy. Therefore, in this case, the correction process may be omitted.
[0068] In each of the above embodiments, the mobile terminal 10 determines that the drop has occurred, when the acceleration in one direction reaches a threshold value or higher, of the accelerations in the triaxial directions. However, not only in the above aspect, the mobile terminal 10 estimates an out-of-range acceleration, for the accelerations in a plurality of directions. The terminal may determine that the drop has occurred, for the first time, when the estimated values in biaxial directions or triaxial directions become a predetermined threshold value or higher, of these estimated values. In this case, different values may be set for the respective three kinds of axial directions, as the threshold values. Further, the mobile terminal 10 estimates an out-of-range acceleration for the accelerations in a plurality of directions, and obtains a weighted average of the estimated values. When the resultant estimated value becomes a predetermined threshold value or higher, the mobile terminal 10 may determine that the drop has occurred. In this case, there is no need to set different values for three kinds of axis directions, as the threshold value, and one threshold value is simply set for the estimated value as a weighted average. There are some dropping manners, and the accelerations are generated in different directions in accordance with the dropping manners. Thus, at the impact on the mobile terminal 10 , the acceleration values in the axial directions vary in accordance with the dropping manner. The mobile terminal 10 can realize the drop determination based on the acceleration value close to the actual state, in consideration of not only the acceleration in one direction but also the accelerations in a plurality of axial directions, during the determination of the occurrence of the drop. This results in improving the accuracy and reliability of the drop determination of the mobile terminal 10 .
[0069] Further, for calculation of the slope, it is not necessary to calculate the slope using the sampling value of the adjacent acceleration. That is, in the first embodiment, the mobile terminal 10 uses the sampling values a 1 and a 2 that are adjacent to each other, to calculate the slope right before the excess of the range. In the second embodiment also, the mobile terminal 10 uses the sampling values b 5 and b 6 that are adjacent to each other, to calculate the slope right after returning into the range. However, the mobile terminal 10 may calculate the value of the slope using the non-adjacent sampling values. For example, when the sampling period is 1 ms, the slope of the acceleration may be calculated from the sampling values at intervals of 2 ms or 3 ms.
[0070] For calculation of the slope, on each exceeding of the range and returning into the range, the mobile terminal 10 may calculate the values of a plurality of slopes and obtain their average value. Now, the mobile terminal 10 can estimate the acceleration and determine the drop, based on a more accurate slope value, with less variation (fluctuation) than a case in which slope values are used respectively for right and left. This results in improving the determination accuracy and reliability of the determination on the mobile terminal 10 . Further, when calculating the average value of a plurality of slopes, the mobile terminal 10 can obtain the average value (weighted average) which has been obtained by weighting a slope value close to the outside range (4 G), based on the assumption that it is closer to the actual state. The variation in the slops can further be restrained, thus enabling to estimate the acceleration and to determine the drop based on the reliable slope value. As a result, it is possible to further improve the determination accuracy and reliability of the determination on the mobile terminal 10 .
[0071] In addition, in each of the above-described embodiment, the mobile terminal 10 calculates the slope using the sampling values of at least two points. However, it is not limited to this, and the slope can be calculated using the sampling value of any one point and also 4 G as the slope value at the exceeding of or returning into the range. According to the above aspect, from the perspective of estimating the acceleration value outside the range with high accuracy, the mobile terminal 10 preferably uses the sampling value which is as close as possible to the outside of the range, for calculation of the above-described slope. For example, in the first embodiment (see FIG. 5 ), it is preferred to use the sampling value a 2 rather than the value a 1 , in combination with the acceleration value (4 G) at the time t 1 . For example, in the second embodiment (see FIG. 8 ), it is preferred to use the sampling value b 5 rather than the value b 6 , in combination with the acceleration value (4 G) at the time t 4 . Then, the mobile terminal 10 can estimate the acceleration value, using the slope at the moment of overrange and the slope at the moment of returning into the range. Thus, the mobile terminal 10 can determine the drop, based on the acceleration value which is as close as possible to the outside of the range. As a result, it is possible to improve the accuracy of the drop determination. It is not necessary to calculate the slope value in the above aspect for both of the exceeding side of and returning side into the range. The calculation may be performed only for either one side (for example, the exceeding side of the range).
[0072] In each of the above-described embodiment, for the conversion from the acceleration estimated value at impact into the actual measurement value, the mobile terminal 10 refers to the acceleration conversion tables 141 a and 141 b . However, it may obtain the actual measurement value using the estimated value, using a predetermined calculation formula.
[0073] Further, in each of the above-described embodiments, the descriptions have been made to the mobile terminal determining the occurrence of the drop, and the dropping has been adopted as one example of movement involving high acceleration. However, the present invention is not limited to this, and may be applied to any movement other than the dropping, such as throwing onto a wall surface and collision with an object. In each of the above-described embodiments, the descriptions have been made on the assumption that the mobile terminal is a mobile phone, a smartphone, a PDA (Personal Digital Assistant). However, the present invention is not limited to the mobile terminal, and is applicable to various electronic devices having a low range acceleration sensor.
[0074] Each of the constituent elements of the mobile terminal 10 illustrated in FIG. 1 is not necessarily configured physically as illustrated in the drawings. That is, specific aspects of division and integration of the devices are not limited to those illustrated in the drawings, and the entirety or a part thereof may be physically or functionally divided or integrated in the units of arbitrary forms in accordance with various loads or the usages. For example, the sampling processing unit 12 , the impact calculating unit 13 , and the application processing unit 14 may be integrated as one constituent element. On the contrary, the impact calculating unit 13 may be divided into a part calculating the slope right before the excess of the range, a part calculating the slope right after returning into the range, and a part calculating the impact time and the acceleration at that time. The application processing unit 14 may be divided into a part converting the acceleration (estimated value) at impact into an actual measurement value, and a part determining the occurrence of the drop. The memory 10 c may be connected through a network or a cable, as an external unit of the mobile terminal 10 .
[0075] According to one aspect of the drop determining device of the present application, an advantageous effect thereof is to determine the drop using a low range acceleration sensor.
[0076] All examples and conditional language provided herein are intended for the pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventor to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although one or more embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
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A drop determining device includes a memory and a processor coupled to the memory. The processor executes a process including: detecting acceleration within a predetermined range; calculating acceleration outside the predetermined range, using the acceleration detected at the detecting; and determining whether drop has occurred, using the acceleration calculated at the calculating.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to sense amplifiers and, more particularly, to a sense amplifier that has a bias circuit with a reduced size.
2. Description of the Related Art
A dynamic random access memory (DRAM) cell is a memory device that retains data stored in the cell for only a short period of time even when power is continuously applied to the cell. As a result, a DRAM cell must be periodically refreshed to maintain the data stored in the cell.
FIG. 1 shows a cross-sectional diagram that illustrates a conventional DRAM cell 100. As shown in FIG. 1, DRAM cell 100 includes an access transistor 102 which is formed in a p-type material 110, and a capacitor 104 which is connected to transistor 102.
Access transistor 102, in turn, includes spaced-apart source and drain regions 112 and 114 which are formed in material 110, and a channel region 116 which is defined between regions 112 and 114. In addition, transistor 102 also includes an access gate 120 which is insulatively formed over channel region 116.
As further shown in FIG. 1, capacitor 104 includes a lower plate 124 which is connected to drain region 114, a dielectric layer 126 which is formed over lower plate 124, and an upper plate 128 which is formed over dielectric layer 126.
In operation, a logic "one" is written to DRAM cell 100 by first placing a programming voltage, such as five volts, on source region 112 while a storage voltage, such as five volts, is applied to the top plate 128 of capacitor 104 and ground is applied to material 110. The storage voltage (which is continuously applied to top plate 128) attracts electrons to the lower plate 124 of capacitor 104 where the electrons begin to accumulate.
After placing a programming voltage on source region 112, access gate 120 is pulsed with an access voltage. This pulse turns on access transistor 102 which causes the electrons on the lower plate 124 of capacitor 104 to flow to source region 112.
The electrons flow from the lower plate 124 of capacitor 104 to source region 112 because the lower plate 124 of capacitor 104 has a potential which is less than five volts (some of the applied voltage is dropped across dielectric layer 126), while source region 112 is at five volts.
When the trailing edge of the pulse again turns off access transistor 102, a positive potential is stored on the lower plate 124 of capacitor 104 due to the decreased number of electrons which are present on the lower plate 124 of capacitor 104.
This positive potential, however, lasts only a short time because electrons from leakage currents are readily attracted to the positive potential. As a result, the positive charge stored on the lower plate 124 of capacitor 104 must be "refreshed" by periodically removing the electrons from the lower plate 124 of capacitor 104.
DRAM cell 100 is erased (a logic "zero" is written to a DRAM cell which already has a logic "one" stored in the cell) by placing ground on source region 112. Once ground has been applied to source region 112, access gate 120 is again pulsed with the access voltage.
This pulse turns on access transistor 102 which causes the electrons in source region 112 to flow to the lower plate 124 of capacitor 104. The electrons flow from source region 112 to the lower plate 124 of capacitor 104 because the lower plate 124 of capacitor 104 has a greater potential than source region 112.
When the trailing edge of the pulse again turns off access transistor 102, the positive potential stored on the lower plate 124 of capacitor 104 is removed due to the increased number of electrons which are again present on the lower plate 124 of capacitor 104.
Due to the overhead required to refresh DRAM cells, large numbers of DRAM cells like cell 100 are typically grouped together to form a memory array. FIG. 2 shows a schematic diagram that illustrates a conventional DRAM array 200.
As shown in FIG. 2, DRAM array 200 includes a plurality of DRAM cells 100 which are formed in rows and columns in two segments S1 and S2. As further shown in FIG. 2, array 200 also includes a plurality of first bit lines BL1-BLm and a plurality of second bit lines BLC1-BLCm.
The first bit lines BL1-BLm are formed adjacent to the columns of cells in first segment S1 so that each bit line BL is connected to all of the source regions 112 in a column of cells. Similarly, the second bit lines BLC1-BLCm are formed adjacent to the columns of cells in second segment S2 so that each bit line BLC is connected to all of the source regions 112 in a column of cells.
Array 200 further includes a plurality of first word lines WL1-WLn and a plurality of second word lines WLC1-WLCn. The first word lines WL1-WLn are formed adjacent to the rows of cells in first segment S1 so that each word line WL is connected to all of the access gates 120 in a row of cells. Similarly, the second word lines WLC1-WLCn are formed adjacent to the rows of cells in second segment S2 so that each word line WLC is connected to all of the access gates 120 in a row of cells.
As additionally shown in FIG. 2, array 200 includes a sense circuit 210 which has a plurality of sense amplifiers SA1-SAm that are connected to the bit lines BL1-BLm and BLC1-BLCm so that each sense amplifier SA is connected to a bit line from each segment S1 and S2.
Each sense amplifier SA includes a first invertor which is formed from transistors M1 and M3, and a second invertor which is formed from transistors M2 and M4. In addition, each sense amplifier SA also includes a power switch transistor M5 and a ground switch transistor M6.
Each power switch transistor M5 provides power to a sense amplifier SA when a first turn on voltage is applied to a power switch line PSL, while each ground switch transistor M6 connects ground to a sense amplifier SA when a second turn on voltage is applied to a ground switch line GSL.
In operation, a cell is programmed by placing a programming voltage, such as five volts, on the bit line that corresponds with the cell to be programmed, while ground is applied to the remaining bit lines. (A storage voltage, such as five volts, is continuously applied to the top plate 128 of each capacitor 104 and ground is applied to material 110.)
After placing a programming voltage on the bit line, the word line that corresponds with the cell to be programmed is pulsed with an access voltage while ground is applied to the remainder of the word lines. This pulse turns on the access transistor 102 which causes the electrons on the lower plate 124 of capacitor 104 to flow to source region 112.
For example, if cell A in FIG. 2 is to be programmed, the programming voltage is applied to bit line BL1 while ground is applied to bit lines BL2-BLm and BLC1-BLCm. In addition, word line WL1 is pulsed with the access voltage while word lines WL2-WLn and WLC-WLCn are connected to ground.
To read a row of cells, ground is placed on the bit lines in the segment that contain the row of cells to be read, while a logic high voltage is placed on the bit lines in the remaining segment. (Since the sense amplifiers SA are based on cross-coupled inverters, the logic states on the bit lines in one segment are always the opposite of the logic states on the bit lines in the other segment.) Once the voltages have been placed on the bit lines, the bit lines are isolated so that the bit lines are only connected to the sense amplifiers SA.
After this, a read voltage, such as five volts, is applied to the word line that corresponds to the row of cells to be read, while ground is applied to the remainder of the word lines. If a cell in the row is storing a logic zero, nothing happens.
On the other hand, if a cell in the row is storing a logic one, the positive potential on the capacitor in the cell raises the voltage on the bit line which, in turn, causes the inverters in the sense amplifier to flip. The logic state stored by is the cell is then determined by reading the state of the inverters. Since the read step is similar to the step of erasing a programmed cell, each programmed cell must be refreshed after it is read.
For example, if the first row of cells in segment 2 is to be read, ground is placed on bit lines BLC1-BLCm, while a logic high voltage is placed on bit lines BL1-BLm. Once the bit lines have been isolated, the read voltage is applied to word line WLC1 while ground is applied to word lines WLC2-WLCn and WL1-WLn.
One problem with array 200 is that when ground is applied to a bit line during a read operation of the array, each programmed cell 100 in the same column of cells 100 that has access gate 120 connected to ground also has a small sub-threshold leakage current that flows from drain region 114 to source region 112 which, in turn, undesirably erases the cell.
One technique for reducing this sub-threshold leakage current is to place a small positive voltage, e.g., 0.1-0.3 volts, rather than ground on the bit lines that are to be read. One technique for providing this small positive voltage is to use sense amplifiers that are biased by the small positive voltage.
FIG. 3 shows a schematic diagram that illustrates a conventional sense circuit 300. As shown in FIG. 3, sense circuit 300 is similar to sense circuit 210 of FIG. 2 and, as a result, utilizes the same reference numerals to designate the structures which are common to both amplifiers.
As shown in FIG. 3, sense circuit 300 differs from sense circuit 210 in that sense circuit 300 includes a bias circuit 310. Bias circuit 310, in turn, includes a first current source GEN1, a transistor M7 which has a drain and gate connected to current source GEN1, and a resistor R1 which is connected to the source of transistor M7 and ground.
In addition, bias circuit 310 also includes a second current source GEN2, a transistor M8 which has a source, a drain connected to current source GEN2, and a gate connected to the gate of transistor M7; and a transistor M9 which has a source connected to ground, a drain connected to the source of transistor M8, and a gate connected to current source GEN2.
In operation, the output of generator GEN1 is set so that a small positive reference voltage is dropped across resistor R1 in response to a reference current IREF flowing through transistor M7 and resistor R1.
The reference voltage and the reference current IREF are mirrored so that a bias voltage VLB equal to the reference voltage is present at a summing node NS (the source of transistor M8 and the drain of transistor M9), and so that a bias current ILB equal to the reference current IREF flows through transistor M8.
Summing node NS sums the bias current ILB and a sense amp current IS. When each transistor MS and M6 is turned off, the sense amp current IS, which represents the total current flowing out of the sense amplifiers SA, is substantially zero. In this case, transistor M9 sinks substantially only the bias current ILB.
On the other hand, when each transistor MS and M6 is turned on, the sense amp current IS is large. In this case, the voltage on node B rises in response to the increased current flow from the sense amplifiers SA which, in turn, turns transistor M9 on harder to sink a larger current that includes both the bias current ILB and the large sense amp current IS.
Thus, by forming a bias voltage VLB at the summing node NS, the voltage on a bit line during a read operation is equal to the bias voltage VLB plus the voltage drops across transistors M6 and transistors M3 or M4, depending on which segment is read.
One problem with bias circuit 310, however, is that bias circuit 310 consumes a significant amount of area. Thus, there is a need for a sense amplifier which has a bias circuit that consumes less silicon real estate.
SUMMARY OF THE INVENTION
A sense amplifier in accordance with the present invention places a low positive voltage, such as 0.1 to 0.3 volts, on a bit line instead of ground when a memory cell is read by utilizing a current source circuit to output a reference current that biases a Schottky diode. The Schottky diode, in turn, can be formed to consume significantly less silicon real estate than the bias circuits conventionally used.
The sense amplifier of the present invention includes a detection circuit which is connected to a bit line and a memory line, a first switch which is connected to the detection circuit, and a second switch which is connected to the detection circuit.
In accordance with the present invention, the sense amplifier also includes a bias circuit which is connected to the second switch. The bias circuit has a current source circuit which is connected to the second switch, and a first Schottky diode which has an input connected to the second switch. The current source circuit sources a reference current which is sunk by the first Schottky diode.
A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description and accompanying drawings which set forth an illustrative embodiment in which the principals of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional diagram illustrating a conventional DRAM cell 100.
FIG. 2 is a schematic diagram illustrating a conventional DRAM array 200.
FIG. 3 is a schematic diagram illustrating a conventional sense circuit 300.
FIG. 4 is a schematic diagram illustrating a bias circuit 400 in accordance with the present invention.
FIG. 5 is a schematic diagram illustrating a sense amplifier 500 in accordance with the present invention.
FIG. 6 is a schematic diagram illustrating a bias circuit 600 in accordance with the present invention.
FIG. 7 is a schematic diagram illustrating a sense amplifier 700 in accordance with the present invention.
FIG. 8 is a schematic diagram illustrating a bias circuit 800 in accordance with the present invention.
FIG. 9 is a schematic diagram illustrating a sense amplifier 900 in accordance with the present invention.
FIG. 10 is a schematic diagram illustrating a sense amplifier 1000 in accordance with the present invention.
FIGS. 11A-11B are a pair of graphs illustrating the I/V relationship of a Schottky diode which has titanium silicide (TiSi 2 ) formed over a lightly-doped n-type region.
FIGS. 12A-12B are a pair of graphs illustrating the I/V relationship of a Schottky diode which has titanium silicide (TiSi 2 ) formed over a lightly-doped p-type region.
FIGS. 13A-13B are a pair of graphs illustrating the I/V relationship of a Schottky diode which has cobalt silicide (CoSi 2 ) formed over a lightly-doped n-type region.
FIGS. 14A-14B are a pair of graphs illustrating the I/V relationship of a Schottky diode which has cobalt silicide (CoSi 2 ) formed over a lightly-doped p-type region.
DETAILED DESCRIPTION
FIG. 4 shows a schematic diagram that illustrates a bias circuit 400 in accordance with the present invention. As shown in FIG. 4, bias circuit 400 includes a current generator GEN that sources a small reference current IREF, and a Schottky diode 410 which has an input connected to generator GEN and an output connected to ground. In operation, diode 410 is biased by the reference current IREF to produce a small positive bias voltage VLB, e.g., 0.1 to 0.3 volts, at the input to diode 410.
FIG. 5 shows a schematic diagram that illustrates a sense amplifier 500 in accordance with the present invention. As shown in FIG. 5, amplifier 500 includes a detection circuit 510 which is connected to a bit line 512 and a memory line 514, such as a bit line or a reference line. (Sense amplifier 500 can be connected to two bit lines, or to a bit line and a reference line where the reference line is used to set the logic state of the bit line.)
Detection circuit 510 includes a first inverter 516 which has an output connected to bit line 512 and an input connected to memory line 514. Inverter 516 is implemented with a p-channel transistor M1 and a n-channel transistor M3. Transistor M1 has a source, a drain connected to bit line 512, and a gate connected to memory line 514. Transistor M3 has a source, a drain connected to the drain of transistor M1, and a gate connected to memory line 514.
Detection circuit 510 also includes a second inverter 518 which has an output connected to memory line 514 and an input connected to bit line 512. Inverter 518 is implemented with a p-channel transistor M2 and a n-channel transistor M4.
Transistor M2 has a source connected to the source of transistor M1, a drain connected to memory line 514, and a gate connected to bit line 512. Transistor M4 has a source connected to the source of transistor M3, a drain connected to the drain of transistor M3, and a gate connected to bit line 512.
As further shown in FIG. 5, sense amplifier 500 also includes a first switch which is implemented with a p-channel transistor MS, and a second switch which is implemented with a n-channel transistor M6. Transistor MS has a source connected to a power node, a drain connected to the sources of transistors M1 and M2, and a gate connected to a first control line C1. Transistor M6 has a source, a drain connected to the sources of transistors M3 and M4, and a gate connected to a second control line C2.
In accordance with the present invention, sense amplifier 500 further includes bias circuit 400 which has the input of Schottky diode 410 connected to the source of switch M6.
In operation, once a first logic state has been placed on bit line 512 and a second logic state has been placed on memory line 514, control line C1 is lowered to turn on transistor M5 while control line C2 is raised to turn on transistor M6.
The line 512 or 514 which has the logic high state turns on the n-channel transistor M3 or M4 which has a drain connected to the opposite line 512 or 514. As a result, the voltage on the opposite line 512 or 514 is equal to the bias voltage VLB plus the voltage drops associated with transistors M3 or M4, and M6.
For example, if a logic low is placed on bit line 512 and a logic high is placed on memory line 514, transistor M1 is turned off and transistor M3 is turned on. In addition, transistor M2 is turned on and transistor M4 is turned off. Thus, with transistors M3 and M6 turned on, the voltage on bit line 512 is equal to the bias voltage VLB plus the voltage drops associated with transistors M3 and M6.
FIG. 6 shows a schematic diagram that illustrates a bias circuit 600 in accordance with the present invention. Bias circuit 600 is similar to bias circuit 400 and, as a result, utilizes the same reference numerals to designate the structures which are common to both circuits.
As shown in FIG. 6, bias circuit 600 differs from bias circuit 400 in that the current generator GEN in circuit 400 is implemented in circuit 600 with a Schottky diode 610 which has an input connected to a power node and an output connected to the input of Schottky diode 410. In operation, Schottky diode 610 is formed so that diode 610 has a reverse-bias leakage current IL that functions as the reference current IREF.
FIG. 7 shows a schematic diagram that illustrates a sense amplifier 700 in accordance with the present invention. Sense amplifier 700 is similar to sense amplifier 500 and, as a result, utilizes the same reference numerals to designate the structures which are common to both amplifiers.
As shown in FIG. 7, sense amplifier 700 differs from sense amplifier 500 in that amplifier 700 utilizes bias circuit 600 rather than bias circuit 400. Sense amplifier 700 operates the same as sense amplifier 500.
FIG. 8 shows a schematic diagram that illustrates a bias circuit 800 in accordance with the present invention. Bias circuit 800 is similar to bias circuit 400 and, as a result, utilizes the same reference numerals to designate the structures which are common to both circuits.
As shown in FIG. 8, bias circuit 800 differs from bias circuit 400 in that the current generator GEN in circuit 400 is implemented in circuit 800 with a current mirror 810. As further shown in FIG. 8, current mirror 810 includes a first transistor M1 which has a source connected to a power supply node, a drain, and a gate connected to the drain.
In addition, current mirror 810 also includes a resistor R1 which is connected to the drain of transistor M1 and ground, and a second transistor M2 which has a source connected to the power supply node, a drain connected to the input of Schottky diode 410, and a gate connected to the gate of the first transistor M1.
In operation, resistor R1 defines a reference current IREF which flows through diode-connected transistor M1 and resistor R1. The reference current IREF is mirrored by transistor M2, and is sufficient to bias Schottky diode 410 to set the low positive bias voltage VLB at the input of diode 410.
FIG. 9 shows a schematic diagram that illustrates a sense amplifier 900 in accordance with the present invention. Sense amplifier 900 is similar to sense amplifier 500 and, as a result, utilizes the same reference numerals to designate the structures which are common to both amplifiers.
As shown in FIG. 9, sense amplifier 900 differs from sense amplifier 500 in that amplifier 900 utilizes bias circuit 800 rather than bias circuit 400. Sense amplifier 900 operates the same as sense amplifier 500.
FIG. 10 shows a schematic diagram that illustrates a sense amplifier 1000 in accordance with the present invention. As shown in FIG. 10, sense amplifier 1000 includes a detection circuit 1010 which is connected to a bit line 1012 and a memory line 1014, such as a bit line or a reference line.
Detection circuit 1010 includes a first inverter 1016 which has an output connected to bit line 1012 and an input connected to memory line 1014. Inverter 1016 is implemented with a p-channel transistor M1, bias circuit 600, and a n-channel transistor M3. Transistor M1 has a source, a drain connected to bit line 1012, and a gate connected to memory line 1014.
Bias circuit 600 has the inputs of Schottky diodes 410 and 610 connected to the drain of transistor M1, while transistor M3 has a source, a drain connected to the output of Schottky diode 410, and a gate connected to memory line 1014.
Detection circuit 1010 also includes a second inverter 1018 which has an output connected to memory line 1014 and an input connected to bit line 1012. Inverter 1018 is implemented with a p-channel transistor M2, bias circuit 600, and a n-channel transistor M4. Transistor M2 has a source connected to the source of transistor M1, a drain connected to memory line 1014, and a gate connected to bit line 1012.
Bias circuit 600 has the inputs of Schottky diodes 410 and 610 connected to the drain of transistor M2, while transistor M4 has a source connected to the source of transistor M3, a drain connected to the output of Schottky diode 410, and a gate connected to bit line 1012.
As further shown in FIG. 10, sense amplifier 1000 also includes a first switch which is implemented with a p-channel transistor MS, and a second switch which is implemented with a n-channel transistor M6. Transistor M5 has a source connected to a power node, a drain connected to the sources of transistors M1 and M2, and a gate connected to a first control line C1. Transistor M6 has a source connected to ground, a drain connected to the sources of transistors M3 and M4, and a gate connected to a second control line C2.
In operation, once a first logic state has been placed on bit line 1012 and a second logic state has been placed on memory line 1014, control line C1 is lowered to turn on transistor M5 while control line C2 is raised to turn on transistor M6.
The line 1012 or 1014 which has the logic high state turns on the n-channel transistor M3 or M4 which has a drain connected to the opposite line 1012 or 1014. As a result, the voltage on the opposite line 1012 or 1014 is equal to the bias voltage VLB plus the voltage drops associated with transistors M3 or M4, and M6.
For example, if a logic low is placed on bit line 1012 and a logic high is placed on memory line 1014, transistor M1 is turned off and transistor M3 is turned on. In addition, transistor M2 is turned on and transistor M4 is turned off. Thus, with transistors M3 and M6 turned on, the voltage on bit line 1012 is equal to the bias voltage VLB plus the voltage drops associated with transistors M3 and M6.
One of the advantages of the present invention is that Schottky diodes consume relatively little silicon real estate. As described in application Ser. No. 09/280,888 (Atty Docket No. NSC1-F1000) for SCHOTTKY DIODE WITH REDUCED S1ZE filed on Mar. 29, 1999 by Alexander Kalnitsky et al., which is hereby incorporated by reference, Schottky diodes can be formed through field oxide regions in a manner which requires little if any additional silicon real estate.
FIGS. 11A-11B show a pair of graphs that illustrate the I/V relationship of a Schottky diode which has titanium silicide (TiSi 2 ) formed over a lightly-doped n-type region, while FIGS. 12A-12B show a pair of graphs that illustrate the I/V relationship of a Schottky diode which has titanium silicide (TiSi 2 ) formed over a lightly-doped p-type region.
FIGS. 13A-13B show a pair of graphs that illustrate the I/V relationship of a Schottky diode which has cobalt silicide (CoSi 2 ) formed over a lightly-doped n-type region, while FIGS. 14A-14B show a pair of graphs that illustrate the I/V relationship of a Schottky diode which has cobalt silicide (CoSi 2 ) formed over a lightly-doped p-type region.
As shown in FIGS. 11A-11B, 12A-12B, 13A-13B, and 14A-14B, another advantage of the present invention is that bias circuits 400, 600, and 800 require only a small current to bias Schottky diode 410 to drop approximately 0.1 to 0.3 volts. As a result, power consumption by the bias circuits is very low.
It should be understood that various alternatives to the embodiment of the invention described herein may be employed in practicing the invention. Thus, it is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.
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A sense amplifier places a low positive voltage, such as 0.1 to 0.3 volts, on a bit line instead of ground when a memory cell is read by utilizing a current source circuit to output a reference current that biases a Schottky diode. The current source circuit is implemented with a Schottky diode that utilizes the reverse-biased leakage current of the diode to form the reference current. The current source circuit can also be implemented with a current mirror circuit.
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FIELD OF THE INVENTION
[0001] This invention relates generally to construction and more particularly, to safety systems and methods to employ during construction.
BACKGROUND
[0002] During construction of large buildings, and even smaller buildings, there are often many concrete structures, such as floors, that have openings in them. These openings may be temporary during the actual construction of the building or they may be permanent features of the building. The purposes of the openings can vary widely. Some permit passageway of materials and equipment during the construction process or some may provide openings for conduit and duct work that will become part of the building upon completion.
[0003] These openings present a safety hazard to the workers on the construction site and many ad-hoc methods of addressing the safety concerns have been developed. For example, one common method that is deployed as needed is simply power-nailing a piece of plywood over the hole to prevent a worker from falling in or through the hole. Because damaging the concrete surface is discouraged during construction, the nails used are often relatively short and, thus, do not provide great security and fastening strength. Furthermore, removing the sheet of plywood to temporarily provide access to the hole is difficult and the nails can not be re-used.
[0004] Often many of the openings are ultimately re-filled as part of the construction process. Thus, some type of re-enforcing structure is utilized underneath an opening to support the concrete that is poured into the opening and allowed to set and cure. Thus, this requires the construction of other structures that can also potentially damage the concrete surface or, at the very least, be difficult to accomplish by one person.
[0005] There remains a need in the industry to address these and other needs as described below with respect to various embodiments of the present invention.
SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention relate to a safety device and method for construction sites that provide secure and easy fastening of a sheet material over an opening in a concrete slab. By covering the opening, injuries and other risks posed by openings can be avoided. Holes are formed through the concrete around the opening and then a two part fastener is used to securely hold the sheet material (e.g., plywood). This approach also allows easy configuration of a method to re-fill the openings with concrete if desired.
[0007] It is understood that other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only various embodiments of the invention by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 depicts a support structure that is useful in accordance with the principles of the present invention for forming holes in concrete structures that allow safety devices and techniques to be utilized therein.
[0009] FIG. 2 illustrates the structure of FIG. 1 in operational use.
[0010] FIG. 3 depicts an opening in a concrete slab 202 that has adjacent through holes 302 , 304 in accordance with the principles of the present invention.
[0011] FIG. 4 shows a top view of an opening 202 having one example pattern of through-holes in accordance with the principles of the present invention.
[0012] FIG. 5 depicts the top view of FIG. 4 but with a sheet of plywood or other material secured over the opening in accordance with the principles of the present invention.
[0013] FIGS. 6 and 7 depict a side view of the two part fastener constructed in accordance with the principles of the present invention.
[0014] FIGS. 8-10 depict a detailed view of the fastener of FIGS. 6 and 7 .
[0015] FIGS. 11 and 12 depict embodiments of the present invention in use with a whaler 1102 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the invention and is not intended to represent the only embodiments in which the invention may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without these specific details. In some instances, well known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the invention.
[0017] FIG. 1 depicts a support structure that is useful, in accordance with the principles of the present invention for forming holes in concrete structures that allow safety devices and techniques to be utilized therein. The support structure 100 is depicted as a tripod-like device having three legs 102 , 104 , 106 . However, one of ordinary skill will recognize that a different number of legs could be used without departing from the scope of the present invention. Typical wire used for such a structure 100 can include, for example, the wire used for #9 and #10 wire chairs.
[0018] The legs 102 , 104 , 106 support two rings 108 , 110 . These rings are used to hold a dowel 112 in a generally upright position. Thus, the inner diameter of the rings 108 . 110 are sized to snugly match the outside diameter of the dowel 112 . One exemplary dowel 112 could be constructed from a length of PVC pipe that is readily available on most job sites. For example, using ¾ inch PVC pipe will result in a hole that accommodates a fastener device described later. The support structure 100 rests securely on a form 114 . Some or all of the legs 102 , 104 , 106 may include an opening, or loop that will hold a nail 116 or other fastener for securing the structure 100 in place on the form 114 .
[0019] As for material, the support structure is beneficially constructed from light weight steel. However, composite materials as well as plastics may be used as well. In operation, the structure 100 will be placed in a poured concrete form and thus will be strong enough to withstand the pressures and forces of such an environment. The inside of the rings 108 , 110 are preferably treated with some type of release agent so that the dowel 112 is easily removable from the structure 100 . Although a dowel is usually round in shape, other shaped (e.g., ellipses, square, etc.) may be used but some of the benefits provided by a round shape will not be realized.
[0020] FIG. 2 illustrates the structure of FIG. 1 in operational use. Only one structure is shown in FIG. 2 ; however, multiple such structures would typically be used as described further herein. The structure 100 is placed within a concrete structure 204 (prior to pouring. This structure 204 includes an opening 202 that creates a safety risk for the workers during construction. FIG. 2 depicts how a sheet of plywood or other material 200 can be placed over the opening 202 . One of ordinary skill will recognize that different dimensions can be used for the structure 100 based on the thickness of the slab of concrete 204 . Also, different coatings and materials can be used for the structure 100 . For example, if a steel tripod structure is used, then the bottom inch or so of the legs can be dipped in plastic or other material.
[0021] In general, however, there are certain dimensions that can be utilized to provide particular benefits. For example, the distance “C” between the structure 100 and the opening 202 can be at least 4 inches. This will provide sufficient strength for the resulting hole. Also, the distance “A” can preferably be at least one inch form the top of the slap 204 to avoid any discoloration or other blemish to the surface of the slab 204 . For similar reasons, the distance “B” can preferably be 1 inch as well. These distances will also provide a structure that can securely hold the dowel 112 in the desired upright position.
[0022] Once the concrete slab 204 is poured and cured, the dowels 112 is removed to create a through-hole 302 adjacent the opening 202 . FIG. 3 depicts an opening in a concrete slab 202 that has adjacent through holes 302 . 304 in accordance with the principles of the present invention.
[0023] FIG. 4 shows a top view of an opening 202 having one example pattern of through-holes in accordance with the principles of the present invention. The figure shows 6 holes 302 , 304 , 402 arranged around the perimeter of the opening 202 . Using fewer holes or using more holes, is contemplated within the scope of the present invention. For example, if a particular spacing (e.g. every 12 inches) between holes is desired, then sufficient holes to address any sized opening can be used.
[0024] FIG. 5 depicts the top view of FIG. 4 but with a sheet of plywood or other material secured over the opening in accordance with the principles of the present invention. In this example, only four holes were used so four fasteners 502 , 4504 , 506 , 508 are used. These fasteners may, for example, be painted bright orange (or red, or fluorescent, etc.) to be visibly distinct. In operation, they securely hold the plywood 200 over the opening but will allow its removal relatively easily.
[0025] FIGS. 6 and 7 depict a side view of the two part fastener constructed in accordance with the principles of the present invention. The fastener has a bent bolt 602 with a top structure that fits over the edge of the plywood 200 . This bolt 602 extends through the hole in the concrete slab and is threaded to match a nut 604 . As shown in FIG. 7 , the nut 604 is sized sufficiently to hold a bottom sheet of plywood 702 in place as well. The bolt and nut can be painted or otherwise adorned with high-visibility markings to help further reduce risks of accidents on the work site.
[0026] FIGS. 8-10 depict a detailed view of the fastener of FIGS. 6 and 7 . The nut 604 has a threaded opening 802 that mates with the threads 1002 of the bent bolt 602 . The nut 604 has a number of purposes and can be sized in a variety of dimensions without departing from the scope of the present invention. Similarly, the bent bolt 602 can be used in varying thicknesses of concrete and thus must have a shaft 1004 that is long enough to extend through the slab for which it is being used. On a work site, workers appreciate tools that are easy to use and can be manipulated while wearing work gloves and using the other tools on hand without requiring specialized equipment. Thus, the bolt 602 and nut 604 are sized to allow hammering and banging with typical hammers on a job site.
[0027] For example, the height “A” of the nut 604 is preferably about 2 inches with the lip “B” being about ¼ inch thick. The diameter “D” is approximately 4½ inches with an opening “E” roughly ½ inch in diameter. The resulting flange “C” is around 2 inches.
[0028] As explained herein, the fastener structure ( 602 , 604 ) may be used to hold an upper and lower sheet of plywood as well as a whaler (See FIG. 11 ). If the plywood is assumed to be ¾ inches thick and the whaler is a standard 2×4, then the following dimensions provide for a beneficial bolt 602 and nut 604 . One of ordinary skill will recognize that these dimensions are merely an example and that the sizes may be modified to accommodate different sized support material. The bolt 602 can have a length “F” of the bent portion that is about 2 inches and if the shaft 1004 is about ½ inch thick, then the holding portion “G” is about 1½ inches. Thus, a worker would cut a piece of plywood to size to fit an opening yet extend towards a hole such that the bolt 602 would overlap and hold the plywood. The thickness “J” can be around 1 inch as such a thickness will allow it to be easily struck by a hammer.
[0029] The inside bolt length “I” depends on the thickness of the slab. In practice, for example, the length should accommodate two pieces of ¾ in plywood, a 2×4 (roughly 4 inches wide) and the 2 inches of the nut 604 . Thus, the inside length “I” is preferably the thickness of the slab plus 7½ inches. For example, then, a ten inch slab would require a bolt 602 having an inside length “I” of 17½ inches. The minimum thread length “H” will have to accommodate the most minimal use which would be a single sheet of plywood. Thus, the minimum thread length “H” is the inside length “I” minus the slab thickness and ¾ inches. In the example bolt above for a 10″ slab, the inside length “I” was 17½ inches and, thus, the minimum thread length “H” is 6¾ inches. Again, one of ordinary skill will recognize that these lengths are exemplary only and other variations may be used without departing from the scope of the present invention.
[0030] FIGS. 11 and 12 depict embodiments of the present invention in use with a whaler 1102 . Such a whaler 1102 would be used across the bottom of an opening to hold plywood 702 in place when re-filling the opening with concrete. As shown, the flange of the nut 604 is sized to accommodate the 2×4 1102 . Also visible in FIG. 11 is the part 1104 of the nut 604 that is orthogonal to the plane of the drawing page. This part 1104 can be repeated around the nut 604 so that a user has multiple striking surfaces by which to tighten the nut 604 .
[0031] In practice, a piece of plywood is cut to fit an opening and multiple bolts 602 are inserted in the holes along the perimeter of the opening. From below, the nuts 604 are threaded on the bolts 602 and tightened using a hammer or similar device. As mentioned earlier, an additional sheet of plywood and whaler can be used beneath the opening as well. From above, a worker can simply strike the bolt 602 to turn it 90 degrees so that it no longer overlaps the plywood. This allows the plywood to me removed (as needed) and then reattached by simply reversing the process to return the bolts 602 to a position where they overlap the plywood. From below, the nuts 604 can be removed without any coordination from above in order to add or remove a sheet of plywood and whaler. Because of the intended environment, the bolts and nuts are constructed from high strength materials such as steel or similar material. In addition, hardened steel or even more durable materials may be utilized if desired. Further-more, the openings shown in the attached figures have been roughly rectangular in shape. However, other shapes and even irregular shapes can be accommodated without departing from the scope of the present invention.
[0032] The previous description is provided to enable any person skilled in the art to practice the various embodiments described herein. Various modifications lo these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments. Thus, the claims are not intended to be limited to the embodiments shown herein, but are to be accorded the full scope consistent with each claim's language, wherein reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” All structural and functional equivalents to the elements of the various embodiments described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.”
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A safely device and method for construction sites provide secure and easy fastening of a sheet material over an opening in a concrete slab. By covering the opening, injuries and other risks posed by openings can be avoided. Holes are formed through the concrete around the opening and then a two part fastener is used to securely hold the sheet material (e.g., plywood).
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RELATED APPLICATIONS
[0001] This application relates to, claims priority from, and incorporates herein by reference, as if fully set forth, U.S. Provisional Patent Application Ser. No. 61/464,578 filed on Mar. 7, 2011 and entitled “METHOD AND APPARATUS FOR PASSING SUTURE THROUGH SOFT TISSUE.”
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to system, methods, and apparatus for enhancing the advancement and retention of suture through tissue.
[0004] 2. Description of Prior Art and Related Information
[0005] Suturing apparatus in the past have had an elongate shaft and a low profile distal clamping mechanism to facilitate their use through cannulas in less invasive surgery. These devices have typically included opposing jaws which clamp onto the tissue to be sutured. The end segment of the suture is pre-positioned and secured at the distal end of one jaw member. Beyond the clamping motion, the mechanism for passing a suture between the jaws and through the tissue incorporates a bendable flat needle. The bendable needle advances distally within the jaw member, bringing it in contact with a segment of the suture. The needle has a notch which engages and secures the suture to carry it forward. This distal advancement of the bendable needle also results in the leading end of the needle to approach and engage a ramp in the jaw member, deflecting the bendable needle in a direction toward the opposing jaw. The bending of the needle requires a high force and results in excess strain on the notched needle component. Fracture and failure of the bendable needle is a concern. Additionally, capturing suture reliably after being passed through the tissue is also a feature not currently offered by the existing technologies. The ability to throw a horizontal mattress stitch with the desired stitch width without having to remove and reload the instrument is currently an unmet need. Another area of improvement is the need to clamp onto thick tissue and reliably pass suture.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, structures and associated methods are disclosed which address these needs and overcome the deficiencies of the prior art. The following description includes an example of the methods and devices within the scope of this disclosure. It is also contemplated that combinations of aspects of various embodiments as well as the combination of the various embodiments themselves is within the scope of this disclosure.
[0007] In one aspect, a suturing device, or apparatus, comprises of a distal tip and jaw, movable with respect to each other, a bendable, tubular needle housed in distal tip and adapted to carry a suture, and a suture receiver disposed on the opposing jaw. The device includes a suture driving assembly for positioning a suture in a tissue section, the assembly comprising at least one needle assembly having a tissue piercing end distal to an elongate shaped section, the elongate shaped section having a curvilinear shape, the elongate shaped section being elastically deformable when restrained into a strained state and upon release assumes the curvilinear shape, the suture coupled to the needle assembly; a shaft having a tip with a tissue engaging surface at a distal end, at least one constraining channel and a pivoting jaw with at least one retrieving channel, each of which having an opening at the tissue engaging surface; such that when the elongate shaped section of the needle assembly is in the restraining portion, the elongate shaped section is deformed into the strained state and when the elongate shaped section advances through the guide segment portion, the elongate shaped section assumes the curvilinear shape, upon continued advancement the elongated shaped section exits through the opening of constraining channel in the curvilinear shape; a suture retriever assembly located in the pivoting jaw.
[0008] The needle assembly as well as the number of needle assemblies can vary depending upon the type of suture stitch required. For example, the device can include a single needle assembly having a single shaped section or multiple shaped sections. In alternate variations, the assembly comprises two or more needle assemblies; the needle assemblies as well as the shaped portions used in any particular suture driving mechanism need not have the same shape. Instead, a single suture driving assembly can use needle assemblies of differing shapes at the same time; however, the spacing and relation of the constraining channel and the retrieval channel shall be adjusted to accommodate a particular shape and configuration of a particular needle assembly.
[0009] The suture devices and methods described herein can include a needle assembly comprising a needle lumen extending through at least the tissue piercing end and where the suture is removably positioned on the distal end of the needle; in another variation, a single suture can be affixed at both ends to a pair of needle assemblies where the needle assemblies comprise two shaped sections with each having a tissue piercing end.
[0010] Sutures used in the present devices and methods can be front loaded into a needle assembly; as a result, a suture retriever assembly can remove the suture from the needle assembly via a front portion of the needle assembly; in one example, the suture retriever assembly comprises at least one pawl member that reduces an opening of the retrieving channel to less than a size of the needle assembly and suture, where the pawl member in a first position allows the needle assembly and suture to move in a first direction and prohibits suture movement in a second direction.
[0011] The devices described herein can be combined with various other medical implements to aid in the suturing of tissue.
[0012] In another variation, a suture driving assembly for placing suture in a tissue section can include a first needle assembly having a tissue piercing end distal and being elastically deformable when restrained into a strained state and upon release assumes the curvilinear shape; a suture exterior to the needle assembly and having at least one end front-loaded onto the distal end of a needle of a first tissue piercing portion of the first needle assembly; a cleat is supported in the needle lumen and extends from the distal end of the needle lumen to engage the suture, thus preventing the bifurcation of the suture from sliding down the shaft of the needle; a shaft having a tissue engaging surface at a distal end, at least one constraining channel, and a pivoting jaw with at least one retrieving channel, each of which having an opening at the tissue engaging surface; where the constraining channel extends through the shaft tip and comprises at least a restraining portion having a profile to maintain the needle assembly into the strained state and a guide segment portion adjacent to the constraining channel opening and having a profile to release needle assembly into the curvilinear shape when advanced there through and upon continued advancement the needle assembly exits the opening of the constraining channel in the curvilinear shape; a suture retriever assembly located in the needle retrieving channel and comprising a pawl mechanism, where the pawl mechanism interferes with the front loaded suture and needle assembly when advanced therein, where rearward movement of the front loaded suture and needle assembly causes the pawl to engage the suture to retain the suture within the needle retrieving channel.
[0013] In another variation, the method may further include advancing a plurality of needle assembly pairs, where each needle assembly pair is coupled to an end of a suture and where each needle assembly advances from a respective constraining channel into a respective guide segment, where the guide segment permits the shaped section of the respective needle assembly located therein to revert to the curvilinear shape prior to leaving the respective guide segment and enter the wall of the organ; and where the plurality of needle assemblies move through the curvilinear shape so that the tissue piercing distal end of each needle assembly pair re-enter the main body at a respective retrieving channel.
[0014] As described above, the method optionally includes the use of front-loaded sutures. Such sutures allow for securing the suture in the retrieving channel by advancing the needle assembly and suture against a pawl mechanism such that the pawl mechanism compresses the suture to retain the suture while allowing the needle assembly to be withdrawn back into the constraining channel
[0015] In certain variations, the suture driving assembly can be used to drive a needle without any suture. In such a case, the needle may be left within the tissue (to be removed later, to be absorbed by the native tissue, or for permanent placement.) Accordingly, needle driving assemblies having the same or similar structures disclosed herein are within the scope of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Further features and advantages will become apparent from the following and more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings, and in which like referenced characters generally refer to the same parts or elements throughout the views, arid in which:
[0017] FIGS. 1A-C . show side views of a preferred embodiment of a suture passing device in various stages of deployment.
[0018] FIG. 2A . is a side view of a preferred notchless tubular needle having a preformed memory shape.
[0019] FIG. 2B . is a side view of a preformed tubular needle in a sheathed, constrained state.
[0020] FIG. 3A . is a side view of the preferred device's tip and suture prior to loading.
[0021] FIG. 3B . is a perspective view of the tip with slot formed in a lower jaw.
[0022] FIG. 3C . is a perspective view of the tip, tubular needle, and suture.
[0023] FIG. 4A . is a perspective view of the tip, tubular needle, cleat, and suture.
[0024] FIG. 4B . is a perspective view of the device's tubular needle and prong cleat.
[0025] FIG. 4C . is a perspective view of the device's prong cleat.
[0026] FIG. 5A . is a perspective view of the device's tubular needle and lateral post cleat.
[0027] FIG. 5B . is a perspective view of the device's lateral post cleat.
[0028] FIG. 5C . is a perspective view of the device's tip, tubular needle, cleat, and suture.
[0029] FIG. 6A . is a partial side view of the tubular needle extended to carry the suture through the aperture of the jaw and pawl.
[0030] FIG. 6B . is a perspective view of the tubular needle extended to carry the suture through the aperture of the jaw and pawl.
[0031] FIG. 6C . is a perspective view of the suture captured by the pawl.
[0032] FIG. 6D . is a side view of the suture captured by the pawl.
[0033] FIG. 7A . is a perspective view of a preferred embodiment having two tubular needles and jaw.
[0034] FIG. 7B . is a perspective view of the left tubular needle extended in the jaw.
[0035] FIG. 7C . is a side view of the device's hand grip, toggle switch and needle assemblies.
[0036] FIG. 7D . is a perspective view of the right tubular needle extended in the jaw.
[0037] FIG. 8A . is a side view of tip with slot and floating pivot in the collapsed state.
[0038] FIG. 8B . is a perspective view mechanism for the floating pivot.
[0039] FIG. 8C . is a side view of tip with slot and floating pivot in the expanded state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] Before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified apparatus, systems, structures or methods as such may, of course, vary. Thus, although a number of apparatus, systems and methods similar or equivalent to those described herein can be used in the practice of the present invention, the preferred apparatus, systems, structures and methods are described herein,
[0041] It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only and is not intended to be limiting.
[0042] Unless defined otherwise, all technical arid scientific terms used herein have the same meaning as commonly understood by one having ordinary skill in the art to which the invention pertains.
[0043] Further, all publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety.
[0044] As used in this specification and the appended claims, the singular forms “a, “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to “an active” includes two or more such actives and the like.
[0045] Further, ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
[0046] It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “approximately” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “approximately 10” is also disclosed. It is also understood that when a value is disclosed that “less than or equal to” the value, “greater than or equal to the value” and possible ranges between values are also disclosed, as appropriately understood by the skilled artisan. For example, if the value “10” is disclosed then “less than or equal to 10”, as well as “greater than or equal to 10” is also disclosed.
[0047] In the following detailed description, reference is made to various specific embodiments in which the invention may be practiced. These embodiments are described with sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be employed, and that structural and logical changes may be made without departing from the spirit or scope of the present invention.
[0048] The present invention relates generally to systems and methods for the driving of a needle or suture through or into body tissue (typically, the needle will be affixed to a suture that remains in the tissue) using a cannula, introducer or other minimally invasive means. The methods and devices described herein can be used in any number of medical procedures, including but not limited to, approximating tissue (e.g., bring separated tissue together), ligating tissue (e.g., encircling or tying off), and fixating of tissue (attaching tissue to another structure or different tissue).
[0049] The term “endoscopy” encompasses arthroscopy, laparoscopy, hysteroscopy, among others, and endoscopic surgery involves the performance of surgical procedures within a patient's body through small openings as opposed to conventional open surgery through large incisions.
[0050] Both open and endoscopic surgical procedures often require sutures to ligate, join or otherwise treat tissue. Generally, suture needles with attached suture strands are grasped either manually or by forceps and passed through the desired work site so a knot can be tied. While the procedures are fairly uncomplicated in open surgery where most suture sites are readily accessible, in endoscopic procedures, where access to the work site is not readily available, the surgeon must use auxiliary devices to be able to grasp the suture strands and pass them through desired tissue.
[0051] Referring now to the images where like elements are represented by like reference numerals. FIG. 1A illustrates a suture passing device, or instrument, of the present invention having an elongated tubular body 10 , a hand grip 20 , a tip 30 , a jaw 40 , an actuator 50 and a needle assembly 60 . With actuator 50 , a surgeon may seize and maintain tissue by movement of jaw 40 against tip 30 as shown in FIG. 1B . Using actuator 50 , a surgeon may also deploy needle assembly 60 with tubular needle 70 carrying a suture 71 through tissue, as described below.
[0052] FIG. 2A Shows a preferred notchless tubular needle 70 in its natural state. As used throughout the specification, “notchless” shall refer to the absence of notches, slots, eyelets, or other such transverse openings for receiving suture as typically formed in needles of prior art suture passers.
[0053] The distal end of the needle 80 is formed in a non-straight geometry. FIG. 2B . shows a tubular needle 70 with the formed end 80 sheathed in a constraining channel 91 . The channel for the needle also includes a curvilinear portion 90 , or guidepath, that approximates the same geometry curve as the distal end of the tubular needle 80 , thereby facilitating the consistent return of the needle 70 its preformed curved shape each time the needle 70 exits the channel. The constrained state tubular needle 70 contained in the needle assembly 60 is loaded into the handle end of the tubular body 10 and advanced through a track in the tubular body 10 .
[0054] FIG. 1A . illustrates a hand grip 20 and actuator 50 that provide articulation of jaw 40 relative to tip 30 . The actuator 50 may be coupled to a return spring that biases the actuator 50 in the open position as seen in FIG. 1A . A surgeon may rotate actuator 50 approximately five to ten degrees, and preferably seven degrees, toward hand grip 20 to close jaw 40 , as seen in FIG. 1B . A surgeon may then rotate actuator 50 approximately an additional thirty to forty degrees, and preferably thirty four degrees, towards hand grip 20 to activate tubular needle 70 , extending it to its natural state 80 , seen in FIG. 1C . The initial additional actuator rotation could require a significant resistance from a spring in the handle mechanism. This significant resistance on the actuator 50 acts as an indicator for the operator to know the tubular needle 70 is beginning to be deployed. Releasing the actuator 50 to its resting, open position returns tubular needle 70 to its constrained state 90 and then disengages jaw 40 to the open position.
[0055] In FIG. 3A . a loop of suture 71 is loaded into distal end of tip 30 with slot 31 , seen in FIG. 3B . The slot 31 allows spring action for gripping the loop of suture 71 when the loop of suture is pulled into the tip 30 . In one embodiment, shown in FIG. 3C ., tubular needle 70 pierces the loop of suture 71 and creates a bifurcation 72 in the suture. When additional force is applied to the suture, the bifurcation 72 will advance along the shaft of the needle. To prevent the bifurcation 70 from advancing along the shaft of the needle, a prong cleat 73 , illustrated in FIG. 4A . is positioned to pierce the loop of suture 71 loop in second location. The pierce of the prong cleat may partially engage the thickness of the suture or create a second bifurcation 74 in the suture. The prong cleat 72 is a wire rod or tube housed within the lumen of the tubular needle with a sharp distal tip 73 , shown in FIG. 4C , that slightly extends from the lumen of the tubular needle 70 , as seen in FIG. 4B . The two piercing objects at different locations in the suture act in conjunction to stabilize the suture from advancing along the shaft of the needle.
[0056] In another embodiment, shown in FIG. 3C ., tubular needle 70 pierces the loop of suture 71 and creates a bifurcation 72 in the suture. When additional force is applied to the suture, the bifurcation 72 will advance along the shaft of the needle. To prevent the bifurcation 72 from advancing along the shaft of the needle, a lateral post cleat 75 , illustrated in FIG. 4A . is positioned to engage the bifurcated section of the suture, FIG. 5C . The body of the lateral post cleat 75 is housed inside the lumen of the tubular needle 70 . Tension on the loop of suture 71 pulls the bifurcated legs of the suture against the lateral post 76 , preventing the suture from sliding down the shaft of the needle.
[0057] FIG. 6B . shows an aperture 41 in jaw 40 that tubular needle 70 and suture 71 pass through, as seen in FIG. 6A . A retractable pawl 42 is sideably positioned on jaw 40 . Retractable pawl 42 includes a window 43 that aligns with aperture 41 when extended forward in the open position. With tubular needle 70 and suture 71 deployed within aperture 41 by rotation of the actuator 50 , the retractable pawl is then actuated to a reward position. The mechanism to actuate reward motion of the retractable pawl 42 may include a spring bias to provide a relatively constant load of the retractable pawl 42 against the deployed tubular needle 70 and suture 71 . Upon release of the actuator 50 , a spring in the actuator mechanism returns the tubular needle 70 to the constraining channel 90 . The spring bias of the retractable pawl 42 allows the tubular needle to return, yet maintains a grip on the suture 71 and pulls it in a reward movement to become captured in between the proximal edge 44 of the aperture 41 in the jaw 40 and distal edge of pawl window 43 , as is shown in FIG. 6C and 6D . Complete release of the actuator 50 disengages the jaw 40 to the open position, thus completing the passage of suture through the tissue.
[0058] In some variations, the suture passing device may be composed to have two or more tubular needles 70 . In one embodiment, the suture passing device can throw more than one segment of suture through tissue simultaneously. The segments of suture being passed by multiple tubular needles may be attached to form a continuous loop of suture, thus enabling the formation of a desired suture pattern, i.e. horizontal mattress stitch. FIG. 7A . shows a left tubular needle 74 and a right tubular needle 75 after being simultaneously released to their natural states 80 . In another embodiment, the device may throw two or more tubular needles 70 through tissue sequentially. The segments of suture being passed by multiple tubular needles may be attached to form a continuous loop of suture, thus enabling the formation of a desired suture pattern, i.e. horizontal mattress stitch. The handle mechanism could be configured to deploy the left needle assembly 64 and right needle assembly 65 independently. FIG. 7C shows the handle mechanism with a switch 61 to toggle and engage one needle assembly at a time in the drive track 60 . Suture could be loaded to the tips of both needle assemblies (as described above) before entering the device down the cannula. With the switch 61 toggled to engage the left needle assembly 64 , the jaw could be actuated to grasp a desired location of tissue and the left tubular needle 74 deployed to pass suture and capture suture in a first tissue location. FIG. 7B . shows a left tubular needle 74 released to its natural state 80 (suture is not shown in image). Fully releasing the actuator 50 returns the left tubular needle 74 to its constrained state 90 and disengages jaw 40 . The suture passing instrument may then be repositioned to a second desired tissue location. A surgeon could then select right needle assembly 65 by toggling the needle track 60 on the instrument's body 10 , as seen in FIG. 7C . With the switch 61 toggled to engage the right needle assembly 65 , the jaw could be actuated to grasp a second desired location of tissue and the right tubular needle 75 deployed to pass suture and capture suture in a second tissue location. FIG. 7D . shows a right tubular needle 75 released to its natural state 80 (suture is not shown in image). . Fully releasing the actuator 50 returns the right tubular needle 75 to its constrained state 90 and disengages jaw 40 from tissue. The suture passing instrument may then be removed from the cannula to expose the two ends of the suture.
[0059] In yet another embodiment, the device described above includes floating a pivot mechanism as shown in FIGS. 8A-C to facilitate a lower profile when the jaws are separated. The jaw 40 includes a pivot interface 36 with linkage 35 . At the opposite end of linkage 35 is another pivot interface 37 that joins linkage 35 and drive rod 38 . The tip 30 includes a slot 31 in which a pin 39 slides within. The pin 39 is fixed to jaw 40 . Axial movement of drive rod 38 in relation to the tip 30 causes jaw 40 to rotate about pin 39 in relationship to the tip 30 . A leaf spring 45 exerts a load against the pin 39 in a direction to bias the pin against the lower end of slot 31 , thus resulting in the jaw 40 in a collapsed state as shown in FIG. 8A . The gap 90 between the inner surfaces of the tip 30 and jaw 40 is minimized. The collapsed state is advantageous for providing a minimum profile for advancing the device through a cannula. The leaf spring segment 45 may be an integral part of the pawl 42 . When the tip 30 and jaw 40 are positioned unto tissue, advancement of the drive rod 38 causes the jaw 40 to rotate about pin 39 to clamp onto the tissue. The resisting force of the tissue to compression between tip 30 and the jaw 40 causes a force on the inner surface of the jaw 40 . If the force on the inner surface of the jaw 40 exceeds the force of the leaf spring 45 to hold the pin 39 against the lower end of slot 31 , the pin will ride up the slot 31 , and effectively increase the gap 90 between the inner surfaces of tip and the jaw 40 , as shown in FIG. 8C . To increase the gap 90 at the axillia acts to distribute the clamp force along the length of the jaw 40 . The distribution of clamp force enables the distal end of jaw 40 to achieve a position in closer proximity to tip 30 .
[0060] The above description and drawings illustrate preferred embodiments which achieve the objects, features and advantages of the present invention. It is not intended that the present invention be limited to the illustrated embodiments. Any modification of the present invention which comes within the spirit and scope of the following claims should be considered part of the present invention.
[0061] 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 embodiments have been set forth only for the purposes of examples and that they should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different ones of the disclosed elements. 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 the generic structure, material or acts of which they represent a single species.
[0062] The definitions of the words or elements of the following claims are, therefore, defined in this specification to not only include the combination of elements which are literally set forth. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
[0063] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what incorporates the essential idea of the invention.
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A suture passing device includes a notchless tubular needle having a preformed curved shape. One or more cleats are disposed within the needle to help secure suture engaged by the sharp distal tip of the needle and to prevent further bifurcation of the suture. The deformable needle is housed in a channel of a lower jaw having a curved guidepath that approximates the curved geometry of the preformed needle, thereby facilitating the consistent return of the needle to its preformed shape each time the needle exits the channel. A dual needle suture passing device is also provided having a second notchless needle to enable a mattress stitch. Methods of loading a suture onto a notchless needle in a suture passer are also provided.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to wood pulp paper with high antimicrobial barrier characteristics suitable for use in sterile packaging such as medical packaging, as well as air or liquid (e.g. water) filtration and other uses.
[0003] 2. Description of the Related Art
[0004] Barrier to microbial penetration is an important and essential property of materials used for packaging medical devices and other items which must be sterilized. Materials currently used in medical packaging include a variety of films, flash-spun polyolefin nonwovens, and medical grade papers. In cases where gas or plasma sterilization (e.g., ethylene oxide, Sterrad®, etc.) is used to sterilize the contents of a package, the package generally includes a film, such as a thermoformed film, forming a bottom web that is heat-sealed to a porous and gas permeable lidding, such as paper or flash-spun polyolefin sheet. Alternately, the package may be in the form of a pouch comprising a porous layer heat-sealed to a film. The porous lidding or layer must allow the sterilant gas or plasma to enter and exit the package to sterilize its contents and at the same time provide a barrier to microbial penetration in order for the medical device or other item packaged therein to remain sterile until it is used.
[0005] The microbial barrier properties of a porous fibrous sheet depend on the average pore size, sheet thickness, size of fibers, fiber morphology, etc. Porous microbial barrier sheets prevent penetration by microbial spores and particles that range in size from sub-micrometer to a few micrometers. The ability of porous sheets to prevent bacterial penetration is measured by their Log Reduction Value (LRV). The higher the LRV value, the better a material is in preventing microbial penetration of the package. For example, the LRV of flash-spun polyolefin sheets used in medical packaging ranges between about 3.2 and 5.5 or higher, as the basis weight (BW) increases from about 1.65 to 2.2 oz/yd 2 (55.9 to 74.6 g/m 2 ). Medical grade papers known in the art typically have LRVs between about 1 and 3, depending on their basis weight, pore size, additive treatments, etc. and are much less effective as microbial barriers than flash-spun materials. An LRV higher by one unit corresponds to a microbial barrier that is ten times more effective. Although natural cellulose pulp papers have been improved through many years of use in medical packaging, their barrier and mechanical properties are deficient in comparison with papers prepared from synthetic materials.
[0006] Koslow, Patent Application Publication No. U.S. 2003/0177909 describes an air filter medium comprising nanofibers. A coating of nanofibers can be used to enhance the performance of filter media. The nanofibers are preferably fibrillated nanofibers. In one embodiment a filter medium is prepared from a blend of fibrillated nanofibers and glass microfibers.
[0007] Bletsos et al., Patent Application Publication No. U.S. 2005/0142973 describes porous fibrous sheets comprising nanofibers or nanofibers and wood pulp, having excellent microbial barrier properties. Certain such sheets have a LRV of at least 5.5.
[0008] Generally, use of nanofibers and increasing their content can increase the barrier properties of nonwoven webs. It would be desirable to improve the barrier properties in a cost-effective manner, such as by using only inexpensive and naturally renewable raw materials. There remains a need for wood pulp-based papers for use in medical packaging having improved microbial barrier properties that are economical compared to primarily synthetic-based microbial barrier sheets.
SUMMARY OF THE INVENTION
[0009] An embodiment of this invention a paper having a Log Reduction Value (LRV) of at least about 3.6, a density of at least about 0.8 g/cm 3 , and a basis weight of at least about 55 g/m 2 , the paper being formed from a fibrous component of wood pulp, wherein the wood pulp is refined pulp having a Canadian Standard Freeness of less than about 360 ml and a weight-weighted mean length of less than about 3 mm.
[0010] Another embodiment of this invention is a multi-ply paper structure, where at least one ply is the paper described above.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The present invention is directed to papers formed from a fibrous component of wood pulp. The papers have improved barrier properties at substantially the same basis weight as known wood pulp papers. Certain wood pulp papers of the present invention are useful as microbial barrier materials, for example in lidding for medical packaging. Certain wood pulp papers of the present invention are also suitable for use in air or liquid filtration.
[0012] “Wood pulp” as used herein refers to the product of boiling wood chips with alkaline liquors or solutions of acidic or neutral salts followed by bleaching with chlorine compounds, the object being to remove more or less completely the hemicelluloses and lignin incrustants of the wood.
[0013] Paper grades used in medical packaging vary in fiber density, porosity, various treatments, additives, and basis weight. Medical papers are bleached and highly refined and are made by the traditional wet laid process using virgin wood pulp. Pre-formed papers used in the art generally have a basis weight of about 1.4 oz/yd 2 (49 g/m 2 ) to 2.9 oz/yd 2 (98 g/m 2 ). Kraft paper is a particular type of paper often used in medical packaging. It is made from kraft pulp and the method for making it involves cooking (digesting) wood chips in an alkaline solution for several hours during which time the chemicals attack the lignin in the wood. The dissolved lignin is later removed leaving behind the cellulose fibers. Unbleached kraft pulp is dark brown in color, so before it can be used in many papermaking applications it must undergo a series of bleaching processes.
[0014] Surprisingly, the inventors have found that using wood pulp having a specific combination of wood pulp freeness and pulp fiber length to prepare papers having a specified apparent density and basis weight results in much higher LRV than wood pulp papers known in the art. The wood pulp-based papers of the present invention have an LRV of at least 3.6, or at least 4, and can be at least 5.
[0015] Wood pulp used to prepare the papers of the present invention has a Canadian Standard Freeness (CSF) less than about 360 ml, preferably less than about 300 ml, and more preferably less than about 250 ml and a weight-weighted mean length of less than about 3 mm, preferably less than about 1.2 mm. The paper of the present invention has an apparent density of at least about 0.80 g/cm 3 . In one embodiment of this invention, the paper has density greater than about 0.80 g/cm 3 and less than about 0.98 g/cm 3 . The papers of the present invention are prepared using methods known in the art such as wet-lay methods to prepare an as-formed paper, which is preferably subsequently calendered. The papers generally have a Gurley Air Resistance (Gurley) no greater than about 250 seconds, even no greater than about 50 seconds.
[0016] The wood pulp used to prepare the paper of the present invention can be unbleached or bleached, hardwood or a combination of hardwood and softwood. In a preferred embodiment of the present invention, the wood pulp is bleached.
[0017] The as-formed paper of the present invention can be prepared using methods known in the art, such as by forming on a Fourdrinier, inclined wire or cylinder-type papermaking machine. The as-formed, dried paper of the present invention preferably has a basis weight of at least about 55 g/m 2 , preferably between about 60 g/m 2 and 120 g/m 2 , more preferably between about 80 g/m 2 and 100 g/m 2 .
[0018] In one embodiment, the paper of the present invention can comprise one or more plies having the same or different wood pulp characteristics in the various plies. For example, one of the plies can be formed from hardwood pulp and another of the plies can be formed from softwood pulp. Alternately, the pulp in one ply can have a different CSF and/or weight-weighted mean length than the pulp used in the other ply. The fibrous or pulp component of the papers of the present invention can consist entirely of wood pulp or consist essentially of wood pulp. The term “consisting essentially of” as used herein is meant to allow for addition of small amounts, less than about 10 weight percent, of additional components. These additional components can include secondary fibers, such as organic or inorganic staple fibers having a denier of at least 0.7 which may be blended with the wood pulp. Examples of suitable fibers that can be blended with the wood pulp include viscose, polyester, polyamide, carbon and others. Other additional components including but not limited to powders, flakes, and pigments can be added in the paper composition, typically at levels between about 1 and 10 weight percent, using methods known in the art.
[0019] In order to achieve the desired density, a paper of the present invention can be calendered using methods known in the art after it is formed. Calendering can be conducted in-line immediately following the paper-forming step or as a separate step, at ambient or elevated temperature, with or without the use of steam or other plasticization agent. Hard nip (metal-metal) or soft nip (metal-filled roll or metal-coated roll) calenders with one or several nips can be used in the calendering process. The calendering conditions (nip pressure, line speed, temperature, etc.) are selected to achieve the desired paper density and LRV using methods known in the art. Generally, the papers are smooth-calendered, however textured or other rolls may be used in the calendering process.
[0020] Multi-ply papers can be prepared wherein the high LRV paper of the present invention is combined with other layers. For example, in a 3-ply paper, an inner ply of the high LRV paper of the present invention is sandwiched between outer plies of conventional papers. For example, the outer plies can comprise wood pulp papers prepared from longer fiber pulp, such as fibers having weight-weighted mean lengths of at least about 3 mm, or between about 3 mm and 6 mm. One or more of the layers comprising the longer pulp fibers may further comprise up to about 70 weight percent of synthetic fibers, such as for example polyamide such as nylon 6,6 or polyester such as poly(ethylene terephthalate) fibers. The synthetic fibers can have a denier per filament of about 0.7 and higher.
[0021] The various layers in the multi-ply paper can be laid down sequentially during the paper forming process and then calendered. Alternately, preformed individual paper plies can be assembled to form a layered structure, which can be calendered subsequently. In the latter embodiment, the individual paper plies can be calendered prior to forming the layered structure and then calendered after assembly of the multi-layer structure. The use of longer fiber plies in a multi-ply structure can improve the mechanical properties of the paper such as tear strength, etc.
[0022] The papers described above are especially suited for use in medical packaging. For example, a lidding component comprising the paper of the present invention can be heat-sealed to a second component of thermoformed film after medical equipment or some other object to be sterilized is placed in the cavity formed by the thermoformed film. A heat seal layer can be extruded or coated on the entire heat seal surface of the lidding, or only onto the areas that need to be sealed to the thermoformed film (known in the art as zone coating) or can be extruded or coated onto the thermoformed film.
TEST METHODS
[0023] In the non-limiting examples that follow, the following test methods were employed to determine various reported characteristics and properties. ASTM refers to the American Society of Testing Materials. TAPPI refers to Technical Association of Pulp and Paper Industry.
[0024] Thickness and Basis Weight of papers were determined in accordance with ASTM D 645 and ASTM D 646, respectively. Thickness measurements were used in the calculation of the apparent density of the papers.
[0025] Apparent Density of papers was determined in accordance with ASTM D 202.
[0026] Gurley Air Resistance (Gurley) for papers was determined by measuring air resistance in seconds per 100 milliliters of cylinder displacement for approximately 6.4 square centimeters circular area of a paper using a pressure differential of 1.22 kPa in accordance with TAPPI T 460.
[0027] Barrier Log Reduction Value (LRV) for papers is a measure of the bacterial barrier properties of a sheet and was determined in accordance with ASTM F 1608. In the test, the top side of a sheet is exposed to a fine aerosol mist containing Bacillus subtilis var. niger spores. Pressure on the bottom side of the web is lowered to achieve an airflow of 2.8 lpm through the sheet. The number of spores reaching both sides of the sheet over 15 minutes is counted. LRV=Log(spore count on the top side)−Log(spore count on the bottom side). Spore count on the top side varies from test to test, but must be at least 1 million.
[0028] Canadian Standard Freeness (CSF) of the pulp is a measure of the rate at which a dilute suspension of pulp may be drained and was determined in accordance with TAPPI Test Method T 227.
[0029] Fiber length (arithmetic mean length, weight-weighted mean length, and length-weighted mean length) was measured in accordance with TAPPI Test Method T 271 using the Fiber Quality Analyzer manufactured by OpTest Equipment Inc.
EXAMPLES
Comparative Example And Example 1
[0030] These examples demonstrate the impact of calendering on paper LRV.
[0031] For Comparative Example A and Example 1, 5.0 g (based on dry weight) of hardwood pulp with CSF of 351 ml, arithmetic mean length 0.36 mm, length-weighted mean length 0.83 mm and weight-weighted mean length 1.25 mm, were placed in a laboratory mixer (British Pulp Evaluation Apparatus, available from Mavis Engineering Ltd., London, England) with about 1600 g of water and agitated for 3 min.
[0032] The dispersion was poured, with 8 liters of water, into an approximately 21 cm×21 cm handsheet mold to form a wet-laid sheet.
[0033] The wet sheet was placed between two pieces of blotting paper, hand couched with a rolling pin and dried in a handsheet dryer at 150° C.
[0034] The hardwood pulp used was Hawesville Hardwood, a fully bleached kraft pulp composed of southern mixed hardwoods supplied by Weyerhaeuser.
[0035] The as-formed paper was Comparative Example A. The paper of Example 1 was made by additionally passing as-formed paper through the nip of a metal-metal calender with a roll diameter of about 20 cm at a temperature of about 23° C., and linear pressure of about 2600 N/cm, (hereafter referred to as “hard calendering” or “hard”).
[0036] Paper properties are shown in Table 1 below. Comparative Example A shows that the apparent density of the as-formed paper was too low to achieve the desired LRV, whereas hard calendering of the paper of Example 1 increased the apparent density to achieve the desired increase in LRV.
Comparative Examples B-C and Example 2
[0037] These papers were formed as described above for Comparative Example A and Example 1, except that hardwood pulp with CSF of 246 ml, arithmetic mean length 0.36 mm, length-weighted mean length 0.80 mm, and weight-weighted mean length 1.08 mm was used.
[0038] Comparative Example B is the as-formed paper. Example 2 was made from the as-formed paper by hard calendering.
[0039] Comparative Example C was made from a sample of the as-formed paper by passing through one nip of a BF Perkins soft nip calender with a metal roll diameter of about 28 cm and a rubber-coated soft roll diameter of about 23 cm at temperature of about 23° C., and linear pressure of about 2000 N/cm (hereafter referred to as “soft calendering” or “soft”).
[0040] Properties of the papers are shown in Table 1 below. Although, the papers of Comparative Examples B-C had a CSF within the range of the present invention, the densities of the papers were low and therefore the desired level of LRV was not achieved. This was true even for Comparative Example C, which was soft calendered.
Comparative Examples D-E
[0041] Paper samples for Comparative Examples D-E were prepared as described above for Comparative Example A and Example 1 correspondingly, except that softwood pulp of 360 ml CSF with arithmetic mean length 1.02 mm, length-weighted mean length 2.85 mm, and weight-weighted mean length 3.74 mm was used. Comparative Example D was as-formed and Comparative Example E was hard-calendered.
[0042] The softwood pulp was Port Wentworth Softwood, which is southern bleached softwood kraft pulp supplied by Weyerhaeuser.
[0043] Properties of the papers are shown in Table 1 below. These examples demonstrate preparation of wood pulp papers having a CSF within the scope of the invention but using softwood pulp (instead of hardwood) and weight-weighted mean length outside the scope of the present invention. Further, even though Comparative Example E was “hard”, the desired LRV was not achieved.
Comparative Examples F-G
[0044] These examples demonstrate preparation of wood pulp papers using softwood pulp having a weight-weighted mean length outside the scope of the present invention.
[0045] Paper samples for Comparative Examples F-G were prepared as described above for Comparative Examples D-E, respectively, using the same softwood pulp but refined to 210 ml CSF with arithmetic mean length 0.84 mm, length-weighted mean length 2.74 mm, and weight-weighted mean length 3.74 mm.
[0046] Properties of the papers are shown in Table 1 below.
Example 3
[0047] This example demonstrates preparation of a hard-nip calendered paper according to the present invention from hardwood pulp.
[0048] The paper sample of Example 3 was prepared as described for Example 1, but using Southern Bleached Hardwood Kraft pulp (supplied by International Paper Company) refined to 104 ml CSF with arithmetic mean length 0.45 mm, length-weighted mean length 0.66 mm and weight-weighted mean length 0.80 mm.
[0049] Properties of the paper are shown in Table 1 below.
Comparative Example H
[0050] This example demonstrates preparation of wood pulp papers using a blend of 50/50 by weight hardwood and soft wood pulps.
[0051] The example was made from 2.5 g (based on dry weight) of hardwood pulp from Comparative Examples B-C with 2.5 grams of softwood pulp from Comparative Examples F-G which were placed together in the laboratory mixer and made as described in Comparative Example A and Example 1. The example was then hard calendered.
[0052] Properties of the paper are shown in Table 1 below.
Example4
[0053] This example demonstrates preparation of two-ply wood pulp papers using a combination of hardwood pulp in one ply and softwood pulp in the second ply, wherein the ratio of hardwood to softwood pulp was 50/50 based on weight.
[0054] The hardwood ply was made from 2.5 g (based on dry weight) of hardwood pulp as used in Example 2 and the softwood ply was made from 2.5 g of the softwood pulp from examples F-G, using the process as described for the foregoing examples.
[0055] Both wet-laid sheets were placed together between two pieces of blotting paper, hand couched with a rolling pin and dried in a handsheet dryer at 1 50° C. The 2-ply paper structure was then hard calendered.
[0056] Properties of the paper are shown in Table 1 below.
Example 5
[0057] This example demonstrates preparation of 2-ply wood pulp papers using a two-ply combination of hardwood pulp in one ply and softwood pulp in the second ply was made the same way as in Example 4, except the hardwood ply was made from 3.75 g (based on dry weight) of hardwood pulp and softwood ply was made from 2.5 g of the softwood pulp, such that the ratio of hardwood to softwood pulp was 75/25 based on weight.
[0058] Properties of the papers are shown in Table 1 below.
Comparative Examples J AND K
[0059] Comparative Examples J and K are commercially available wood pulp based medical papers. Comparative Example J is 45# Impervon® medical paper and Comparative Example K is 60# Impervon® medical paper, both available from Kimberly-Clark Corporation (Neenah, Wis.).
[0060] Properties of the papers are shown in Table 1 below.
TABLE 1 Properties of Wood Pulp Papers Apparent BW, density, Gurley, Example Description LRV g/m2 g/cm 3 sec Comp. A Hardwood; 1.2 102 0.34 2.3 as-formed 1 Hardwood; 3.7 107 0.91 20 hard Comp. B Hardwood; 2.4 99 0.38 4 as-formed 2 Hardwood; 5.3 98 0.92 28 hard Comp. C Hardwood; 2.7 110 0.535 4.2 soft Comp. D Softwood; 1.4 106 0.41 2.3 as-formed Comp. E Softwood; 2 110 0.91 18 hard Comp. F Softwood; 1.0 106 0.4 9.9 as-formed Comp. G Softwood; 2.1 108 0.89 52 hard 3 Hardwood; 5.2 93 0.98 202 hard Comp. H Blended 50/50 2.3 112 0.91 31 softwood/ hardwood; hard 4 2-ply 50/50 3.6 115 0.87 5.8 softwood/ hardwood; hard 5 2-ply 25/75 5.2 108 0.83 8.6 softwood/ hardwood; hard Comp. J Medical paper 1.7 79 0.92 86 45# Comp. K Medical paper 3.4 99 0.80 17 60#
[0061] As can be seen from the data, only a combination of well-refined pulp with short fibers that have been densified to high apparent density (Examples 1-4) can provide LRV significantly above the known wood pulp based papers.
[0062] Densification to about 0.98 g/cm 3 (Example 3) gave relatively high air resistance (Gurley). In several embodiments, the apparent density is less than 0.98 g/cm 3 , but above 0.80 g/cm 3 .
[0063] Blends of hardwood pulp with short fibers and softwood pulp with long fibers (Comparative Example H) did not provide barrier properties within the desired range of the present invention. However, distributing each type of the pulp in a separate ply or layer can give high LRV, which is superior to the prior art samples, if the basis weight of the ply with the short fibers is at least 55 g/m2 (Example 4).
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Wood pulp papers are provided that are useful in end uses requiring microbial barrier properties such as medical packaging, air filters, liquid filters, and other uses and the papers have significantly improved bacterial barrier properties in contrast to wood pulp papers known in the art as measured by Log Reduction Values determined by ASTM F-1608.
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BACKGROUND OF THE INVENTION
This invention generally relates to ink jet printer apparatus and methods and more particularly relates to an ink jet printer with cleaning mechanism having a wiper blade and transducer, and method of assembling the printer.
An ink jet printer produces images on a receiver by ejecting ink droplets onto the receiver in an imagewise fashion. The advantages of non-impact, low-noise, low energy use, and low cost operation in addition to the capability of the printer to print on plain paper are largely responsible for the wide acceptance of ink jet printers in the marketplace.
In this regard, “continuous” ink jet printers utilize electrostatic charging tunnels placed close to the point where ink droplets are being ejected in the form of a stream. Selected ones of the droplets are electrically charged by the charging tunnels. The charged droplets are deflected downstream by the presence of deflector plates that have a predetermined electric potential difference between them. A gutter may be used to intercept the charged droplets, while the uncharged droplets are free to strike the recording medium.
In the case of “on demand” ink jet printers, at every orifice a pressurization actuator is used to produce the ink jet droplet. In this regard, either one of two types of actuators may be used. These two types of actuators are heat actuators and piezoelectric actuators. With respect to heat actuators, a heater placed at a convenient location heats the ink and a quantity of the ink will phase change into a gaseous steam bubble and raise the internal ink pressure sufficiently for an ink droplet to be expelled to the recording medium. With respect to piezoelectric actuators, a piezoelectric material is used, which piezoelectric material possess piezoelectric properties such that an electric field is produced when a mechanical stress is applied. The converse also holds true; that is, an applied electric field will produce a mechanical stress in the material. Some naturally occurring materials possessing this characteristics are quartz and tourmaline. The most commonly produced piezoelectric ceramics are lead zirconate titanate, lead metaniobate, lead titanate, and barium titanate.
Inks for high speed ink jet printers, whether of the “continuous” or “piezoelectric” type, have a number of special characteristics. For example, the ink should incorporate a nondrying characteristic, so that drying of ink in the ink ejection chamber is hindered or slowed to such a state that by occasional spitting of ink droplets, the cavities and corresponding orifices are kept open. The addition of glycol facilitates free flow of ink through the ink jet chamber.
Of course, the ink jet print head is exposed to the environment where the ink jet printing occurs. Thus, the previously mentioned orifices are exposed to many kinds of air born particulates. Particulate debris may accumulate on surfaces formed around the orifices and may accumulate in the orifices and chambers themselves. That is, the ink may combine with such particulate debris to form an interference burr that blocks the orifice or that alters surface wetting to inhibit proper formation of the ink droplet. Also, the ink may simply dry-out and form hardened deposits on the print head surface and in the ink channels. The particulate debris and deposits should be cleaned from the surface and orifice to restore proper droplet formation. In the prior art, this cleaning is commonly accomplished by brushing, wiping, spraying, vacuum suction or spitting of ink through the orifice.
Thus, inks used in ink jet printers can be said to have the following problems: the inks tend to dry-out in and around the orifices resulting in clogging of the orifices; the wiping of the orifice plate causes wear on plate and wiper and the wiper itself produces particles that clog the orifice; cleaning cycles are time consuming and slow productivity of ink jet printers. Moreover, printing rate declines in large format printing where frequent cleaning cycles interrupt the printing of an image. Printing rate also declines in the case when a special printing pattern is initiated to compensate for plugged or badly performing orifices.
Ink jet print head cleaners are known. A wiping system for ink jet print heads is disclosed in U.S. Pat. No. 5,614,930 titled “Orthogonal Rotary Wiping System For Inkjet Printheads” issued Mar. 25, 1997 in the name of William S. Osborne et al. This patent discloses a rotary service station that has a wiper supporting tumbler. The tumbler rotates to wipe the print head along a length of linearly aligned nozzle. In addition, a wiper scraping system scrapes the wipers to clean the wipers. However, Osborne et al. do not disclose use of an external solvent to assist cleaning and also does not disclose complete removal of the external solvent.
Therefore, there is a need to provide a suitable ink jet printer with cleaning mechanism having a wiper blade and transducer, and method of assembling the printer, which cleaning mechanism is capable of simultaneously cleaning the print head surface and ink channels.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an ink jet printer with cleaning mechanism having wiper blade and transducer, and method of assembling the printer, and method of assembling the printer, which cleaning mechanism simultaneously cleans a surface of a print head belonging to the printer as the cleaning mechanism cleans ink channels formed in the print head.
With the above object in view, the invention resides in an ink jet printer, comprising a print head having a surface thereon and an ink channel therein; and a cleaning mechanism associated with said print head and adapted to simultaneously clean contaminant from the surface and the ink channel, said cleaning mechanism including a wiper having a plurality of wicking channels therein alignable with the surface, the wicking channels communicating with a passageway formed in said cleaning mechanism; and a sonic vibrator connected to said wiper for vibrating said wiper, so that said vibrator cleans the contaminant from the surface.
According to an exemplary embodiment of the invention, an ink jet printer comprises a print head having a surface thereon surrounding a plurality of ink ejection orifices. The orifices are in communication with respective ones of a plurality of ink channels formed in the print head. A solvent delivering wiper has a plurality of internal passageways formed therethrough alignable with the surface which delivers a liquid solvent cleaning agent to the surface to flush contaminant from the surface. In this manner, contaminant residing on the surface is entrained in the solvent while the wiper flushes contaminant from the surface. A transducer is integrated in the wiper blade, which is capable of serving three functions. The transducer can be used to produce a mechanical vibration in the wiper, it can be used as the means to pump the cleaning solvent, or it can be used to ultrasonically energize the cleaning solvent. The solvent delivering wiper has a second passageway alignable with the surface which vacuums solvent and entrained contaminant from the surface. To aid in the removal of cleaning solvent and contaminant, wicking channels or groves are provided on the beveled edge of the wiper blade. The previously described wiper and transducer will here-in-below be referred to as a cleaning block. Moreover, a piping circuit is provided for filtering the particulate matter from the solvent and for recirculating clean solvent to the surface of the print head.
In addition, a translation mechanism is connected to the wiper for translating, the wiper across the print head surface. In this regard, the translation mechanism may comprise a lead-screw threadably engaging the wiper. Moreover, a displacement mechanism is connected to the wiper for displacing the wiper to a position proximate the surface of the print head to enable cleaning of the ink channels and the surface of the print head. The cleaning block, associated translation mechanism, and plumbing will be referred to hereinbelow as a cleaning mechanism.
A feature of the present invention is the provision of a cleaning mechanism associated with the print head, which cleaning mechanism is adapted to simultaneously clean contaminant from the print head surface and ink channels.
An advantage of the present invention is that cleaning time is reduced because the print head surface and ink channels are cleaned simultaneously.
These and other objects, features and advantages of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings wherein there are shown and described illustrative embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing-out and distinctly claiming the subject matter of the present invention, it is believed the invention will be better understood from the following detailed description when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a view in plan of a first embodiment ink jet printer, the printer having a reciprocating print head and a pivotable platen roller disposed adjacent the print head;
FIG. 2 is a view in plan of the first embodiment of the printer showing the pivotable platen roller pivoting in an arc outwardly from the print head;
FIG. 3 is a view taken along section line 3 — 3 of FIG. 1, this view showing a cleaning mechanism poised to move to a position adjacent the print head to clean the print head;
FIG. 4 is a view in partial elevation of the print head and adjacent platen roller;
FIG. 5 is a view in elevation of the first embodiment printer, this view showing the cleaning mechanism having been moved into position to clean the print head;
FIG. 6 is a view in perspective of a first embodiment cleaning block belonging to the cleaning mechanism, the first embodiment cleaning block here shown cleaning the print head;
FIG. 7A is an isometric view of the first embodiment cleaning block;
FIG. 7B is an isometric view of the second embodiment cleaning block;
FIG. 7C is an isometric view of the third embodiment cleaning block;
FIG. 8A is a view in vertical section of the first embodiment cleaning block while the first embodiment cleaning block cleans the print head;
FIG. 8B is a view in vertical section of a second embodiment cleaning block while the second embodiment cleaning block cleans the print head;
FIG. 9 is a view in elevation of a second embodiment ink jet printer, this view showing the cleaning mechanism disposed in an upright position and poised to move to a location adjacent the print head to clean the print head, which print head is capable of being pivoted into an upright position;
FIG. 10 is a view in elevation of the second embodiment printer, this view showing the cleaning mechanism having been moved into position to clean the print head not pivoted into an upright position;
FIG. 11 is a view in elevation of a third embodiment ink jet printer, this view showing the print head pivoted into an upright position and poised to move to a location adjacent the upright cleaning mechanism to clean the print head;
FIG. 12 is a view in elevation of the third embodiment printer, this view showing the print head having been moved into position to clean the print head;
FIG. 13 is a view in elevation of a fourth embodiment ink jet printer, this view showing the print head in a horizontal position and poised to move laterally to a location adjacent the cleaning mechanism to clean the print head;
FIG. 14 is a view in elevation of the fourth embodiment printer, this view showing the print head having been moved into position to clean the print head;
FIG. 15 is a view in plan of a fifth embodiment ink jet printer, the printer having a non-reciprocating “page-width” print head;
FIG. 16 is a view taken along section line 16 — 16 of FIG. 15, this view showing the print head in a horizontal position and poised to move laterally to a location adjacent the cleaning mechanism to clean the print head; and
FIG. 17 is a view in elevation of the fifth embodiment printer, this view showing the print head having been moved into position to clean the print head.
DETAILED DESCRIPTION OF THE INVENTION
The present description will be directed in particular to elements forming part of, or cooperating more directly with, apparatus in accordance with the present invention. It is to be understood that elements not specifically shown or described may take various forms well known to those skilled in the art.
Therefore, referring to FIGS. 1 and 2, there is shown a first embodiment ink jet printer, generally referred to as 10 , for printing an image 20 (shown in phantom) on a receiver 30 (also shown in phantom), which may be a reflective-type receiver (e.g., paper) or a transmissive-type receiver (e.g., transparency). Receiver 30 is supported on a platen roller 40 capable of being rotated by a platen roller motor 50 engaging platen roller 40 . Thus, when platen roller motor 50 rotates platen roller 40 , receiver 30 will advance in a direction illustrated by a first arrow 55 . Platen roller 40 is adapted to pivot outwardly about a pivot shaft 57 along an arc 59 for reasons disclosed hereinbelow. Many designs for feeding paper for printing are possible. Another mechanism utilizes a first set of feed rollers to dispose receiver onto a plate for printing. A second set of feed rollers remove the receiver when printing is completed.
Referring to FIGS. 1, 3 and 4 , printer 10 also comprises a reciprocating print head 60 disposed adjacent to platen roller 40 . Print head 60 includes a plurality of ink channels 70 formed therein (only six of which are shown), each channel 70 terminating in a channel outlet 75 . In addition, each channel 70 , which is adapted to hold an ink body 77 therein, is defined by a pair of oppositely disposed parallel side walls 79 a and 79 b. Print head 60 may further include a cover plate 80 having a plurality of orifices 90 formed therethrough colinearly aligned with respective ones of channel outlets 75 , such that each orifice 90 faces receiver 30 . A surface 95 of cover plate 80 surrounds all orifices 90 and also faces receiver 30 . Of course, in order to print image 20 on receiver 30 , an ink droplet 100 is released from ink channel 70 through orifice 90 in direction of receiver 30 along a preferred axis 105 normal to surface 95 , so that droplet 100 is suitably intercepted by receiver 30 . To achieve this result, print head 60 may be a “piezoelectric ink jet” print head formed of a piezoelectric material, such as lead zirconium titanate (PZT). Such a piezoelectric material is mechanically responsive to electrical stimuli so that side walls 79 a/b simultaneously inwardly deform when electrically stimulated. When side walls 79 a/b simultaneously inwardly deform, volume of channel 70 decreases to squeeze ink droplet 100 from channel 70 and through orifice 90 .
Referring again to FIGS. 1, 3 and 4 , a transport mechanism, generally referred to as 110 , is connected to print head 60 for reciprocating print head 60 between a first position 115 a thereof and a second position 115 b (shown in phantom). In this regard, transport mechanism 110 reciprocates print head 60 in direction of a second arrow 117 . Print head 60 slidably engages an elongate guide rail 120 , which guides print head 60 parallel to platen roller 40 while print head 60 is reciprocated. Transport mechanism 110 also comprises a drive belt 130 attached to print head 60 for reciprocating print head 60 between first position 115 a and second position 115 b, as described presently. In this regard, a reversible drive belt motor 140 engages belt 130 , such that belt 130 reciprocates in order that print head 60 reciprocates with respect to platen 40 . Moreover, an encoder strip 150 coupled to print head 60 monitors position of print head 60 as print head 60 reciprocates between first position 115 a and second position 115 b. In addition, a controller 160 is connected to platen roller motor 50 , drive belt motor 140 , encoder strip 150 and print head 60 for controlling operation thereof to suitably form image 20 on receiver 30 . Such a controller may be a Model CompuMotor controller available from Parker Hannifin, Incorporated located in Rohnert Park, Calif.
As best seen in FIG. 4, it has been observed that surface 95 may have contaminant thereon, such as particulate matter 165 . Such particulate matter 165 also may partially or completely obstruct orifice 90 . Particulate matter 165 may be, for example, particles of dirt, dust, metal and/or encrustations of dried ink. The contaminant may also be an unwanted film (e.g., grease, oxide, or the like). Although the description herein refers to particulate matter, it is to be understood that the invention pertains to such unwanted film, as well. Presence of particulate matter 165 is undesirable because when particulate matter 165 completely obstructs orifice 90 , ink droplet 100 is prevented from being ejected from orifice 90 . Also, when particulate matter 165 partially obstructs orifice 90 , flight of ink droplet 105 may be diverted from preferred axis 105 to travel along a non-preferred axis 167 (as shown). If ink droplet 100 travels along non-preferred axis 167 , ink droplet 100 will land on receiver 30 in an unintended location. In this manner, such complete or partial obstruction of orifice 90 leads to printing artifacts such as “banding”, a highly undesirable result. Also, presence of particulate matter 165 on surface 95 may alter surface wetting and inhibit proper formation of droplet 100 . Therefore, it is desirable to clean (i.e., remove) particulate matter 165 to avoid printing artifacts and improper formation of droplet 100 .
Referring to FIGS. 3, 5 , 6 , 7 A, 8 A and 8 B, first embodiment cleaning block 175 includes a solvent delivering wiper 210 with a transducer 180 mounted atop the wiper. Wiper 210 has a first set of multiple internal areaways 220 formed therethrough. Solvent delivering wiper 210 is oriented with respect to surface 95 such that first areaways 220 are alignable with surface 95 for reasons disclosed presently. In this regard, first areaways 220 are alignable with surface 95 for delivering a liquid solvent cleaning agent to surface 95 in order to flush particulate matter 165 from surface 95 (as shown). Of course, particulate matter 165 will be entrained in the solvent as the solvent flushes particulate matter 165 from surface 95 . Wiper 210 may also include a blade portion 225 integrally formed therewith for lifting contaminant 165 from surface 95 as cleaning wiper blade 210 traverses surface 95 in direction of a third arrow 227 . The transducer 180 is mounted atop the cleaning wiper blade 210 by any suitable means known in the art, such as by a suitable screw fastener (not shown). The transducer has a wire harness 195 extending from it, leading to a controller 190 . The transducer is driven via the controller, which produces a mechanical vibration in the cleaning wiper blade 210 . This mechanical vibration produces a shearing type effect in the blade portion 225 as it transverses the printhead surface 95 , which aids in the removal of stubborn particulate matter 165 . It may be understood that wicking channels 230 and a second set of multiple internal cuts 240 in combination with vacuum pump 290 co-act to remove solvent and particulate matter 165 which may have been left by blade portion 225 as blade portion 225 traverses surface 95 (as shown).
As best seen in FIG. 7, a second embodiment cleaning block 242 includes a solvent delivering wiper 210 with a transducer 180 mounted internal to the wiper. The second embodiment cleaning block 242 serves the same function as first embodiment cleaning block 235 with the only exception being in the placement and functionality of transducer 180 . In the second embodiment, the transducer 180 is mounted internal to solvent delivering wiper 210 and serves as an extra means of controlling the solvent flow through first set of multiple internal areaways 220 . The transducer is activated via controller 190 and wiring harness 195 , and is capable of controlling the solvent delivered to the surface 95 .
As best seen in FIG. 7C, a third embodiment cleaning block 244 includes a solvent delivering wiper 210 , a solvent manifold 200 and transducer 180 mounted behind the solvent manifold. The third embodiment cleaning block 244 serves the same function as first embodiment cleaning block 235 and second embodiment 242 . In the third embodiment, solvent manifold 200 is attached to the solvent delivering wiper 210 by any suitable means known in the art, such as by a suitable screw fastener (not shown). Attached to the rear of manifold 200 is transducer 180 also connected by any suitable means known in the art, such as by a suitable screw fastener (not shown). The transducer is connected to and controlled by controller 190 via wiring harness 195 . When the transducer is activated, it ultrasonically energizes the solvent in the manifold. The solvent is ejected onto surface 95 and the removal of particulate 165 is enhanced by the energized solvent.
FIG. 8A shows first embodiment cleaning block 175 in a scraping mode defined as having an angle θ less than 90 degrees. FIG. 8B shows first embodiment cleaning block 175 in a wiping mode defined as having an angle θ greater than 90 degrees.
Returning to FIGS. 3, 5 , 6 , 7 A, 7 B, 8 A, and 8 B, a piping circuit, generally referred to as 250 , is associated with print head 60 for reasons disclosed momentarily. In this regard, piping circuit 250 includes a first piping segment 260 coupled to first areaway 220 formed through wiper 210 . A discharge pump 270 is connected to first piping segment 260 for discharging the solvent into first piping segment 260 . In this manner, the solvent discharges into first set of areaways 220 formed within the wiper 210 and onto surface 95 while discharge pump 270 discharges the solvent into first piping segment 260 . It may be appreciated that the solvent discharged onto surface 95 is chosen such that the solvent also, at least in part, acts as lubricant to lubricate surface 95 . Surface 95 is lubricated in this manner, so that previously mentioned blade portion 225 will not substantially mar, scar, or otherwise damage surface 95 and any electrical circuitry which may be present on surface 95 . In addition, a second piping segment 280 is coupled to a second set of cuts 240 formed within the wiper 210 . A vacuum pump 290 is connected to second piping segment 280 for inducing negative pressure (i.e., pressure less than atmospheric pressure) in second piping segment 280 . Thus, negative pressure is induced in second set of cuts 240 and in second piping segment 280 . As negative pressure is induced on second piping segment 280 , the solvent and entrained particulate matter 165 are vacuumed from surface 95 to enter second set of cuts 240 .
Referring now to third embodiment cleaning block 244 , shown in FIG. 7C, the piping circuit generally referred to as 250 is similar to that in the first and second embodiments previously discussed in detail. The difference in the third embodiment is that first piping segment 260 is coupled to the first set of multiple internal areaways 220 via a passageway internal to solvent manifold 200 . Likewise, second piping segment 280 is coupled to the second set of multiple internal cuts 240 via a passageway internal to solvent manifold 200 . It should be noted that the two passageways in manifold 200 are unconnected, with one being used for the fresh solvent introduced to the wiper and the other used for the “dirty” solvent sucked from surface 95 .
Referring yet again to FIGS. 3, 5 , 6 , 7 A, 7 B, 7 C, 8 A, and 8 B, interposed between first piping segment 260 and second piping segment 280 is a solvent supply reservoir 300 having a supply of the solvent therein. Discharge pump 270 , which is connected to first piping segment 260 , draws the solvent from reservoir 300 and discharges the solvent into second areaways 220 by means of first piping circuit 260 . Hence, it may be appreciated that first piping circuit 260 extends from wiper 210 to reservoir 300 . In addition, vacuum pump 290 , which is connected to second piping segment 280 , pumps the solvent and particulate matter 165 from print head surface 95 toward reservoir 300 . Connected to second piping segment 280 and interposed between vacuum pump 290 and reservoir 300 is a filter 310 for capturing (i.e., separating-out) particulate matter 165 from the solvent, so that the solvent supply in reservoir 300 is free of particulate matter 165 . Of course, when filter 310 becomes saturated with particulate matter 165 , filter 310 is replaced by an operator of printer 10 . Thus, circuit 250 defines a recirculation loop for recirculating contaminant-free solvent across surface 95 to efficiently clean surface 95 . In addition, connected to first segment 260 is a first valve 314 , which first valve 314 is interposed between wiper 210 and discharge pump 270 . Moreover, connected to second segment 280 is a second valve 316 , which second valve 316 is interposed between reservoir 300 and vacuum pump 290 . Presence of first valve 314 and second valve 316 make it more convenient to perform maintenance on cleaning mechanism 170 . That is, first valve 314 and second valve 316 allow cleaning mechanism 170 to be easily taken out-of service f or maintenance. For example, to replace filter 310 , discharge pump 270 is shut-off and first valve 314 is closed. Vacuum pump 290 is operated until solvent and particulate matter are substantially evacuated from second piping segment 280 . At this point, second valve 316 is closed and vacuum pump 290 is shut-off. Next, saturated filter 310 is replaced with a clean filter 310 . Thereafter, cleaning mechanism 170 is returned to service substantially in reverse to steps used to take cleaning mechanism 170 out-of service.
Still referring to FIGS. 3, 5 , 6 , 7 A, 8 A, and 8 B, a translation mechanism, generally referred to as 320 , is connected to cleaning block 175 for translating cleaning block 175 across surface 95 of print head 60 . In this regard, translation mechanism 320 comprises an elongate externally threaded lead-screw 330 threadably engaging cleaning block 175 . Engaging lead-screw 330 is a motor 340 capable of rotating lead-screw 330 , so that cleaning block 175 , traverses surface 95 as lead-screw 330 rotates. In this regard, cleaning block 175 traverses surface 95 in direction of a fourth arrow 345 . In addition, cleaning block 175 is capable of being translated to any location on lead-screw 330 , which preferably extends the length of guide rail 120 . Being able to translate cleaning block 175 to any location on lead-screw 330 allows cleaning block 175 to clean print head 60 wherever print head 60 is located on guide rail 120 . Moreover, connected to motor 340 is a displacement mechanism 350 for displacing cleaning block 175 to a position proximate surface 95 of print head 60 .
Referring now to FIGS. 2, 3 and 5 , platen roller 40 is disposed adjacent to print head 60 and, unless appropriate steps are taken, will interfere with displacing cleaning block 175 to a position proximate surface 95 . Therefore, it is desirable to move platen roller 40 out of interference with cleaning block 175 , so that cleaning block 175 can be displaced proximate surface 95 . Therefore, according to the first embodiment of printer 10 , platen roller 40 is pivoted outwardly about previously mentioned pivot shaft 57 along arc 59 . After platen roller 40 has been pivoted, displacement mechanism 350 is operated to displace cleaning block 175 to a position proximate surface 95 to begin removal of particulate matter 165 from ink channel 70 and surface 95 .
Turning now to FIGS. 9 and 10, there is shown a second embodiment ink jet printer 360 capable of simultaneously removing particulate matter 165 from ink channel 70 and surface 95 . Second embodiment ink jet printer 360 is substantially similar to first embodiment ink jet printer 10 , except that platen roller 40 is fixed (i.e., non-pivoting). Also, according to this second embodiment printer, print head 60 pivots about a pivot pin 370 to an upright position (as shown). Moreover, cleaning mechanism 170 is oriented in an upright position (as shown) and displacement mechanism 350 displaces cleaning block 175 , so that cleaning block is moved to a location proximate surface 95 .
Referring to FIGS. 11 and 12, there is shown a third embodiment ink jet printer 400 capable of simultaneously removing particulate matter 165 from ink channel 70 and surface 95 . Third embodiment ink jet printer 400 is substantially similar to first embodiment ink jet printer 10 , except that platen roller 40 is fixed (i.e., non-pivoting). Also, according to this third embodiment printer, print head 60 pivots about pivot pin 370 to an upright position (as shown) and displacement mechanism 350 displaces printer 400 (except for platen roller 40 ), so that printer 400 is moved to a location proximate cleaning mechanism 170 . Moreover, cleaning mechanism 170 is oriented in a fixed upright position (as shown).
Referring to FIGS. 13 and 14, there is shown a fourth embodiment ink jet printer 410 capable of simultaneously removing particulate matter 165 from ink channel 70 and surface 95 . Fourth embodiment ink jet printer 410 is substantially similar to first embodiment ink jet printer 10 , except that platen roller 40 is fixed (i.e., non-pivoting) and cleaning assembly 170 is off-set from an end portion of platen roller 40 by a distance “X”. Also, according to this third embodiment printer, displacement mechanism 350 displaces printer 410 (except for platen roller 40 ), so that printer 410 is moved to a location proximate cleaning mechanism 170 .
Referring to FIGS. 15, 16 and 17 , there is shown a fifth embodiment ink jet printer, generally referred to as 420 , for printing image 20 on receiver 30 . Second printer 400 is a so-called “page-width” printer capable of printing across width W of receiver 30 without reciprocating across width W. That is, printer 420 comprises print head 60 of length substantially equal to width W. Connected to print head 60 is a carriage 430 adapted to carry print head 60 in direction of first arrow 55 . In this regard, carriage 430 slidably engages an elongate slide member 440 extending parallel to receiver 30 in direction of first arrow 55 . A print head drive motor 450 is connected to carriage 430 for operating carriage 430 , so that carriage 430 slides along slide member 440 in direction of first arrow 55 . As carriage 430 slides along slide member 440 in direction of first arrow 55 , print head 60 also travels in direction of first arrow 55 because print head 60 is connected to carriage 430 . In this manner, print head 60 is capable of printing a plurality of images 20 (as shown) in a single printing pass along length of receiver 30 . In addition, a first feed roller 460 engages receiver 30 for feeding receiver 30 in direction of first arrow 55 after all images 20 have been printed. In this regard, a first feed roller motor 470 engages first feed roller 460 for rotating first feed roller 460 , so that receiver 30 feeds in direction of first arrow 55 . Further, a second feed roller 480 , spaced-apart from first feed roller 460 , may also engage receiver 30 for feeding receiver 30 in direction of first arrow 55 . In this case, a second feed roller motor 490 , synchronized with first feed roller motor 470 , engages second feed roller 480 for rotating second feed roller 480 , so that receiver 30 smoothly feeds in direction of first arrow 55 . Interposed between first feed roller 460 and second feed roller 480 is a support member, such as a stationary flat platen 500 , for supporting receiver 30 thereon as receiver feeds from first feed roller 460 to second feed roller 480 . Of course, previously mentioned controller 160 is connected to print head 60 , print head drive motor 450 , first feed roller motor 470 and second feed roller motor 490 for controlling operation thereof in order to suitably form images 20 on receiver 30 .
Still referring to FIGS. 15, 16 and 17 , according to this fifth embodiment printer 420 , displacement mechanism 350 displaces printer 410 (except for feed rollers 460 / 480 and platen 500 ), so that printer 410 is moved to a location proximate cleaning mechanism 170 .
The solvent cleaning agent mentioned hereinabove may be any suitable liquid solvent composition, such as water, isopropanol, diethylene glycol, diethylene glycol monobutyl ether, octane, acids and bases, surfactant solutions and any combination thereof. Complex liquid compositions may also be used, such as microemulsions, micellar surfactant solutions, vesicles and solid particles dispersed in the liquid.
It may be understood from the teachings hereinabove, that an advantage of the present invention is that cleaning time is reduced. This is so because surface 95 of print head 60 is cleaned of contaminant simultaneously with cleaning ink channels 70 formed in the print head 60 .
While the invention has been described with particular reference to its preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements of the preferred embodiments without departing from the invention. In addition, many modifications may be made to adapt a particular situation and material to a teaching of the present invention without departing from the essential teachings of the invention. For example, with respect to the second embodiment printer 360 , displacement mechanism 350 may be foldable to the upright position from a substantially horizontal position. This configuration of the invention will minimize the external envelope of printer 360 when print head 60 is not being cleaned by cleaning mechanism 170 , so that printer 360 can be located in a confined space with limited headroom. Also, the second set of multiple internal cuts 240 can be replaced with a vacuum canopy described in commonly assigned patent application Ser. No. 09/221,526 filed Dec. 28, 1998 and patent application Ser. No. 09/195,727 filed Nov. 18, 1998. Another example is the addition of a vacuum hood to any of the hereinabove described embodiments. Such a vacuum hood is also disclosed in commonly assigned patent application Ser. No. 09/221,526 filed Dec. 28, 1998 and patent application Ser. No. 09/195,727 filed Nov. 18, 1998.
Therefore, what is provided is an ink jet printer with cleaning mechanism having a wiper blade and transducer, and method of assembling the printer, which cleaning mechanism is capable of simultaneously cleaning the print head surface and ink channels.
Parts List
10 . . . first embodiment ink jet printer
20 . . . image
30 . . . receiver
40 . . . platen roller
50 . . . platen roller motor
55 . . . first arrow
57 . . . pivot shaft
59 . . . arc
60 . . . print head
70 . . . ink channel
75 . . . ink channel outlet
77 . . . ink body
79 a/b . . . side walls
80 . . . cover plate
90 . . . orifice
95 . . . surface
100 . . . ink droplet
105 . . . preferred axis of ink droplet ejection
110 . . . transport mechanism
115 a . . . first position (of print head)
115 b . . . second position (of print head)
117 . . . second arrow
120 . . . guide rail
130 . . . drive belt
140 . . . drive belt motor
150 . . . encoder strip
160 . . . controller
165 . . . particulate matter
167 . . . non-preferred axis of ink droplet ejection
170 . . . cleaning mechanism
175 . . . first embodiment cleaning block
180 . . . transducer
190 . . . transducer controller
195 . . . wiring harness
200 . . . seal solvent manifold
210 . . . cleaning wiper blade
220 . . . areaways
225 . . . blade portion
227 . . . third arrow
230 . . . wicking channels
240 . . . cuts
242 . . . second embodiment cleaning block
244 . . . third embodiment cleaning block
246 . . . wiper portion
250 . . . piping circuit
260 . . . first piping segment
270 . . . discharge pump
280 . . . second piping segment
290 . . . vacuum pump
300 . . . reservoir
310 . . . filter
314 . . . first valve
316 . . . second valve
320 . . . translation mechanism
330 . . . lead-screw
340 . . . motor
345 . . . fourth arrow
350 . . . displacement mechanism
360 . . . second embodiment ink jet printer
370 . . . pivot pin
400 . . . third embodiment ink jet printer
410 . . . fourth embodiment ink jet printer
420 . . . fifth embodiment ink jet printer
430 . . . carriage
440 . . . slide member
450 . . . print head drive motor
460 . . . first feed roller
470 . . . first feed roller motor
480 . . . second feed roller
490 . . . second feed roller motor
500 . . . stationary platen
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An ink jet printer with cleaning mechanism having a wiper blade and transducer, and method of assembling same. The printer comprises a print head having a surface thereon surrounding a plurality of ink ejection orifices. The orifices are in communication with respective ones of a plurality of ink channels formed in the print head. A cleaning liquid delivering wiper is provided as a means to a clean print head. Further, sonic or ultrasonic transducer is provided to energize the wiper and the cleaning liquid flowing through solvent delivering channels in wiper. Contaminant residing on the surface is entrained in the cleaning liquid while the wiper flushes contaminant from the surface. Cleaning liquid and contaminant is transported away through a number of devices; return passageways internal to the wiper in combination with wicking channels, return passageways provided in a canopy, and return passageways provided in a trailing hood. In addition, a piping circuit is associated with the print head for filtering the particulate matter from the solvent and for recirculating clean solvent to the surface of the print head.
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This is a continuation of application Ser. No. 711,815, filed Mar. 14, 1985, now U.S. Pat. No. 4,652,573, issued Mar. 24, 1987.
BACKGROUND OF THE INVENTION
This invention is concerned with certain 1,4-dihydropyridines, their preparation, pharmaceutical compositions containing them and their use as therapeutic agents, particularly as anti-ischaemic and anti-hypertensive agents.
The compounds of the invention delay or prevent the cardiac contracture which is believed to be caused by an accumulation of intracellular calcium under ischaemic conditions. Calcium overload, during ischaemia, can have a number of additional adverse effects which would further compromise the ischaemic myocardium. These include less efficient use of oxygen for ATP production, activation of mitochondrial fatty acid oxidation, and possibly, promotion of cell necrosis. Thus, the compounds are useful in the treatment or prevention of cardiac conditions, such as angina pectoris, cardiac arrythmias, heart attacks and cardiac hypertrophy. The compounds also possess vasodilator activity and are thus useful as antihypertensives and for the treatment of coronary vasospasm.
The compounds of the invention are calcium channel antagonists which are characterized by the presence of certain nitrogen-containing heterocyclic substituents in carboxylic ester groups substituted on the 3 and, optionally, also on the 5 positions of the dihydropyridine ring.
The structure and presumed mode of action of the 1,4-dihydropyridine calcium antagonists have been reviewed recently in the literature, see Meyer, et al., Annual Reports in Medicinal Chemistry, 1983, Chapter 9 and Janis, et al., J. Med. Chem 26, 775 (1983). One of the earliest compounds discovered, and still a standard against which new compounds are measured, is nifedipine (U.S. Pat. No. 3,485,847 to Bossert), in which the 2 and 6 positions are substituted by methyl groups, the 4 position by 2-nitrophenyl and the 3 and 5 positions by carboxylic acid methyl ester groups. Similar compounds are disclosed in U.S. Pat. Nos. 3,455,945; 3,325,505; and 3,441,468 to Loew and Nos. 3,470,297 and 3,511,837 to Bossert, which introduced variations in the 4-substituent. U.S. Pat. Nos. 3,905,970 to Bossert, et al., and 3,985,758 to Marakami, et al., introduced certain mono- or dialkylamino-alkylene and nitrogen-containing heterocyclic alkylene groups into one or both of the 3,5 ester groups. U.S. Pat. Nos. 4,307,103 and 4,393,070 to Sato disclose 1,4-dihydropyridines in which the 2 position is not substituted by alkyl, but instead is substituted with cyano, formyl or certain other substituents and the ester group in the 3 position may contain various substituted alkyl groups including substituted alkyl aminoalkyl, heterocyclic aminoalkyl and aroylaminoalkyl, including phthalimidoethyl. U.S. Pat. No. 4,448,964 to Muto, et al., discloses compounds in which the 3-position ester group contains certain substituted piperidinyl alkylene groups.
It is recognized that useful 1,4-dihydropyridines have a wide variety of structures; however, the need for superior activity and specificity remains, and the effect of any particular structural modification on the properties of the compound is generally unpredictable. This is particularly true of modifications in the esters at the 3 and 5 positions, and of modifications at the 2 and 5 positions.
SUMMARY OF THE INVENTION
According to the invention, there are provided novel compounds of the formula: ##STR3## wherein
R 1 and R 2 are each independently amino, trifluoromethyl, pentafluoroethyl, alkoxy, lower alkenyl, lower alkynyl, straight- or branched-chain lower alkyl which may be substituted with cyano, hydroxy, acyloxy, hydrazino, lower alkylamino, di(lower alkyl) amino, or a 5- or 6-membered saturated nitrogen containing heterocyclic-1-yl, which may in turn be substituted with oxo, hydroxy, lower alkyl and hydroxy(lower alkyl) substituents;
R 3 is straight- or branched-chain C 1 -C 12 alkyl, alkenyl, alkynyl or cycloalkyl optionally containing hydroxy, alkoxy, acyloxy, cyano, di(lower alkyl)amino, 5- or 6-membered saturated nitrogen-containing heterocyclic-1-yl or --A--R 4 , wherein A and R 4 are as defined below;
A is selected from the group consisting of straight-chain, branched-chain, and cyclic hydrocarbon structures containing 2 to 12 carbon atoms with from zero to two double bonds;
R 4 is selected from the group consisting of: ##STR4##
R 5 is hydrogen, nitro, cyano, azido, amino, trifluoromethyl, (lower alkyl)amino, di(lower alkyl)amino, halo, carboxyl, carb-lower alkoxy, lower alkyl, lower alkenyl, lower alkynyl, cyclo(lower)alkyl, (lower acyl)amino, carboxamido, sulphonamido, and SO m -(lower alkyl) (m=0 to 2); and
R 6 is aryl or hetero-aryl, and is phenyl, thienyl, furyl, pyrryl, pyrazolyl, imidazolyl, oxazolyl, isoxazolyl, thiazolyl, pyridyl, pyridazinyl, pyrimidyl, pyrazinyl, quinolyl, isoquinolyl, indolyl or benzimidazolyl, the aryl and the hetero-aryl optionally containing from 1 to 3 identical or different substituents each of which is lower alkyl, lower alkenyl, lower alkynyl, lower alkoxy, lower alkenoxy, lower alkynoxy, dioxy(lower)-alkylene, halogen, trifluoromethyl, hydroxyl, amino, (lower alkyl)amino, di(lower alkyl)amino, nitro, cyano, azido, carboxy, carb(lower)alkoxy, carboxamido, sulphonamido, or SO m -(lower alkyl) or (m=0 to 2), the lower alkyl and lower alkoxy substituents in turn being optionally substituted by lower alkoxy, halogen, carboxyl, carb(lower) alkoxy, amino, lower alkylamino or di(lower alkyl)amino;
or a pharmaceutically acceptable salt thereof.
These compounds are useful in the treatment of coronary insufficiency, angina pectoris and hypertension.
The invention also provides pharmaceutical compositions containing the above novel compounds and a pharmaceutically acceptable carrier. Preferably these compositions are in dosage form comprising a clinically effective amount of the active compound.
The invention further provides a method of antagonizing the utilization of calcium in the body of a human being or animal and of treating the above disorders.
In another embodiment of the invention there is provided a method for preparing the novel compounds.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term "lower" when used to modify alkyl, alkoxy, alkenyl, alkynyl, and acyl shall mean "containing not more than about 6 carbon atoms." The preferred lower alkyls, alkoxys, alkenyls, alkynyls, and acyls contain not more than 4 carbon atoms.
It is particularly desirable that R 1 and R 2 be methyl. Other preferred R 1 and R 2 substituents are ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, allyl, propargyl, amino, trifluoromethyl, (lower alkyl)amino(lower alkyl), especially diethylaminoethyl and cyanomethyl.
In one preferred embodiment, R 1 and R 2 are both methyl. In another preferred embodiment, R 1 is methyl or ethyl and R 2 is not lower alkyl. In another preferred embodiment, R 1 is trifluoromethyl. In another, R 2 is trifluoromethyl. In yet another, both R 1 and R 2 are trifluoromethyl.
The term "5- or 6-membered saturated nitrogen-containing heterocyclic-1-yl" for R 1 , R 2 , and R 3 shall mean a heterocyclic moiety linked to the lower alkyl group through the heterocyclic nitrogen atom, whether or not the nitrogen atom is assigned the number "1". Suitable heterocyclic moieties include pyrrolidinyl, piperazinyl, piperidinyl, 1-methyl-4-piperazinyl, morpholinyl, etc.
"Lower alkylamino" for R 1 and R 2 includes methylamino, ethylamino, 1-propylamino, 2-propylamino, 1-butylamino, 2-butylamino, etc.
"Di-(lower alkyl)-amino" for R 1 , R 2 , and R 3 includes, for example, dimethylamino, N-methyl-N-ethylamino, N,N-diethylamino, N,N-di-(n-propyl)amino, N-methyl-N-propylamino, etc.
Examples of R 3 substituents include methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, 2-hydroxyethyl, 3-hydroxy-butyl, 3-hexenyl, 1,3-butadienyl, acetylenyl, allyl, ethynyl, vinyl, isopropenyl, 2-nonyl-2-butenyl, and cyanomethyl.
Preferred R 3 moieties are --A--R 4 and lower alkyl groups (having one to six carbon atoms). Particularly preferred are methyl, ethyl, and isopropyl.
A is preferably a C 2 to C 6 alkylene group, namely ethylene, propylene, butylene, pentylene, and hexylene. Preferred R 5 substituents are hydrogen, carboxyl, carboxamido, carb(lower) alkoxy, and lower alkyl, particularly methyl and ethyl.
Particularly preferred R 6 moieties are o and m (positions 2, 3, 5, and 6) substituted and disubstituted phenyl, substituted with nitro, trifluoromethyl, cyano, azido, carboxy, carb(lower)-alkoxy, carboxamido, sulfonamido, and SO m -(lower alkyl) where m is 0-2. Most preferred substituents are nitro in particular, as well as trifluoromethyl, cyano, carboxamido, and sulfonamido. Other preferred R 6 groups are pyridyl, furyl, and thienyl, substituted as above.
It will be appreciated that certain compounds of the invention are chiral due to their different ester functions. Accordingly, the invention embraces the pure enantiomers as well as mixtures thereof.
PHARMACEUTICAL FORMULATION
Pharmaceutically acceptable salts of the compounds of the general Formula I are prepared in the conventional manner. Acid addition salts are derived from a therapeutically acceptable acid such as hydrochloric acid, hydrobromic acid, acetic acid, propionic acid and, more preferably, from a di- or poly-basic acid such as phosphoric acid, succinic acid, fumaric acid, citric acid, glutaric acid, citraconic acid, glutaconic acid, tartaric acid, maleic acid or ascorbic acid.
A preferred embodiment of this invention is a method of treatment which comprises administering a therapeutically effective amount of a compound of the above Formula I. In general the daily dose can be from 0.01 mg/kg to 10 mg/kg per day and preferably from 0.2 mg/kg to 4 mg/kg per day, bearing in mind, of course, that in selecting the appropriate dosage in any specific case, consideration must be given to the patient's weight, general health, metabolism, age and other factors which influence response to the drug. The parenteral dosage will be approximately an order of magnitude lower than the oral dosage. Because the activities of the compounds vary somewhat, the effective dosages will also vary. The pharmacological data supplied herewith compare the compounds of the present invention to the known compounds nifedipine and nicardipine, for which clinical dosages have been established. Appropriate dosage levels for each compound can be inferred from these data.
In another embodiment of this invention there are provided pharmaceutical compositions in dosage unit form which comprise from about 1 mg to about 150 mg of a compound of the above formula I, and preferably from about 5 mg to about 100 mg.
The pharmaceutical composition may be in any form suitable for oral use, such as tablets, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents elected from the group consisting of sweetening agents, flavoring agents, coloring agents, and preserving agents in order to provide a pharmaceutically elegant and palatable preparation. Tablets may contain the active ingredient in admixture with non-toxic pharmaceutically acceptable excipients which are suitable for manufacture of tablets. These excipients may be inert diluents, for example calcium carbonate, sodium carbonate, lactose, calcium phosphate; granulating and disintegrating agents, such as corn starch, gelatine or acacia; and lubricating agents, such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period.
Formulations for oral use may also be presented as hard gelatine capsules wherein the active ingredient is mixed with an inert solid diluent, for example calcium carbonate, calcium phosphate or kaoline, or as soft gelative capsules wherein the active ingredient is mixed with an oil medium, for example, arachis oil, liquid paraffin or olive oil.
The present invention also embraces aqueous suspensions containing the active compoud in admixture with suitable pharmacologically-accepted excipients. Such excipients include suspending agents, for example sodium carboxymethylcellulose, methycellulose, hydroxypropylmethylcellulose, sodium alginate, polyvinylpyrrolidone, gum tragacanth and gum acacia; dispersing or wetting agents such as a naturally-occurring phosphatide, for example lecithin, or a condensation products of an alkylene oxide with fatty acids, for example polyoxyethylene stearate, or condensation prodcts of ethylene oxide with long chain aliphatic alcohols, for example heptadecaethyleneoxycetanol, or condensation products of ethylene oxide with partial esters derived from fatty acids and a hexitol, for example polyoxyethylene sorbitol monooleate, or condensation product of ethylene oxide with partial esters derived from fatty acids and hexitol anhydrides, for example polyoxyethylene sorbitan monooleate. The said aqueous suspensions may also contain one or more preservatives, for example ethyl, or n-propyl-p-hydroxy benzoate, one or more coloring agents, one or more flavoring agents, and one or more sweetening agents, such as sucrose, saccharin, aspartame, mannitol, sorbitol, or sodium or calcium cyclamate.
Dispersable powders and granules suitable for preparation of an aqueous suspension by the addition of water provide the active ingredient in admixture with a dispersing or wetting agent, suspending agent, and one or more preservatives. Suitable dispersing or wetting agents and suspending agents are exemplified by those already mentioned above. Additional excipients, for example, sweetening, flavoring, and coloring agents, may also be present.
Syrups and elixirs may be formulated with sweetening agents, for example glycerol, sorbitol or sucrose. Such formulations may also contain a demulcent, a preservative, and flavoring and coloring agents.
The pharmaceutical compositions may also be in the form of a sterile injectable preparation, for example as a sterile injectable aqueous suspension. This suspension may be formulated in a conventional manner using those suitable dispersing or wetting agents and suspending agents which have been mentioned above. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in 1,3-butanediol.
The pharmaceutical compositions may be tableted or otherwise formulated so that for every 100 parts by weight of the composition there are present between 5 and 95 parts by weight of the active ingredient and preferably between 25 and 85 parts by weight of the active ingredient. The dosage unit form for humans will generally contain between about 1 mg and 100 mg of the active ingredient of the Formula I set forth above.
From the foregoing formulation discussion it should be apparent that the compositions of this invention can be administered orally or parenterally. The term parenteral as used herein includes subcutaneous injection, intravenous, intramuscular, or intrasternal injection or infusion techniques.
The compounds of the present invention may also be administered transdermally with the use of an appropriate transdermal vehicle. The preferred vehicle is 1-dodecylazacycloheptan-2-one, disclosed in U.S. Pat. No. 4,405,616.
This invention also incudes a method for treating coronary insufficiency (poor circulation, due to cardiac hypertrophy or to other causes), hypertension, angina pectoris, cardiac arrythmia, heart attack, or coronary vasospasm by administering an effective amount of a compound of the present invention. The invention also compounds a method for effecting calcium channel antagonist activity in a mammal, such as a human, by administering an effective amount of a compound of Formula I.
The compounds of Formula I, above, may be prepared by the following general syntheses:
Process 1
according to the procedure described by Fox, et al., in J. Org. Chem. 16, 1259 (1951): ##STR5## wherein R 1 , R 2 , R 3 , R 4 , A, and R 6 have the same meaning as defined above.
The details of Process No. 1 are as follows:
The molar ratio of the starting materials in the reaction mixture is in the range of from about 1.0:0.8:0.8 to 1.0:4.0:4.0 respectively and preferably from about 1.0:0.9:0.9 to 1.0:1.5:1.5.
The reaction is carried out in the presence or absence of an alcohol such as methanol, ethanol, isopropanol, etc., a halogenated hydrocarbon such as chloroform, carbon tetrachloride, etc., an aromatic hydrocarbon such as benzene, toluene, etc., an ether such as tetrahydrofuran, dioxane, etc., and an aprotic polar solvent such as acetonitrile, dimethyl formamide, water or the like, between room temperature and 150° C., preferably 30° to 100° C. Separation of the desired product from the reaction mixture is effected by conventional operations such as concentration, extraction, recrystallization, and flash chromatography.
Substituted β-ketoesters were prepared by transesterification, thus: ##STR6## (1-1.5 mol) is treated with R 4 --A--OH (1 mol) and ##STR7## (1-1.5 mol) is treated with R 3 --OH (1 mol) in a reaction vessel at 140°-150° C. for 6-12 hours in the presence of small amounts of Na. Ethanol formed is preferably removed by a flow of inert gas through the reaction vessel, thereby forcing the reaction to completion. From the residue, the product is isolated by distillation, flash chromotography or crystallization.
Substituted β-ketoesters, where in R 1 and R 2 are specifically --CH 3 , for example: ##STR8## wherein R 3 and R 4 have the meaning defined above, are prepared by reacting alcohols of the formula R 3 OH and R 4 --A--OH respectively, with a source of ketene, for example diketene, or diketene-acetone adduct in refluxing toluene. A catalytic amount of p-toluenesulfonic acid is used in the alcohol and diketene-acetone adduct reaction and acetone is removed on concentration. The product is purified by distillation, crystallization or flash chromatography. ##STR9##
Substituted β-aminoacrylates, represented by the formulas ##STR10## may be prepared by bubbling ammonia gas into a solution of a β-ketoester in alcohol, preferably methanol or ethanol, at from 5°-25° C. for 5 to 15 hours. The product is isolated by filtration, by distillation under vacuum or by flash chromatography.
The β-aminoacrylates may be also prepared by mixing, for example, 0.5 mole of ethyl or methylacetoacetate in 200 ml of methanol and 100 ml of saturated sodium acetate and passing through the appropriate nitrile (R 3 CN or R 4 CN) for several hours. The reaction mixture is poured into ice water and the organic layer is extracted with ether. The ether solution is dried and concentrated and the residue is distilled. A mixture of about 0.1 mole of said residue and 50 ml of 30% ammonium hydroxide or sodium hydroxide is stirred for a long period. The reaction mixture is extracted with methylene chloride and the methylene chloride extracts are dried and concentrated. Fractional distillation of the residue results in the substituted β-aminoacrylate.
Further, Process Nos. 2-6 are illustrated by the following reaction schemes:
Process 2
according to the procedure described by Loev, et al., J. Med. Chem, 17, 956 (1974): ##STR11##
Process 3
according to the procedure described by Iwanami, et al., Chem. Pharm. Bull. 27, 1426 (1979): ##STR12##
Process 4
according to the procedure described by Iwanami, et. al., Chem. Pharm. Bull. 27, 1426 (1979) ##STR13##
Process 5
according to the procedure described by Shibanuma, et. al., Chem. Pharm. Bull. 28, 2809 (1980) ##STR14##
Process 6
according to the procedure described by Loev, et. al., U.S. Pat. No. 3,511,847 (1970) ##STR15##
The following examples illustrate some preferred embodiments of the present invention.
EXAMPLE 1
2,6-dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-methylphenyl)-5-carbmethoxy-1,4-dihydropyridine
A. 2-hydroxyethyl phthalimide
A suspension of 71.8 g (0.48 mol) of phthalic anhydride in 30.5 g (0.50 mo.) of 2-aminoethanol was swirled resulting in a vigorous exothermic reaction. The swirling was continued until no solid remained. The mixture was located in an oil bath at 100° C. for 30 minutes and, after cooling to room temperature, 200 ml of hot water was added. The product precipitated as a white solid, which was filtered and dried. Yield 56 g (61%); m.p. 120°-125° C. NMR: (CDCl 3 ) δ 3.7 (4H,S), 3.9 (1H,S), 7.5 (4H, m).
B. 2-phthalimidoethyl acetoacetate
Procedure 1: A mixture of 60 g (0.31 mol) of 2-hydroxyethyl phthalimide and 45 g (0.35 mol) of ethyl acetoacetate was heated in an oil bath at 145° C. for 48 hours. Ethanol was removed with nitrogen flow through the flask during the course of the reaction and the residual ethanol was removed under high vacuum. The remaining solid was recrystallized from acetone/diethyl ether/petroleum ether. Yield 40 g (46%); m.p. 87°-90° C.; NMR: (CDCl 3 ) δ 2.2 (3H,S), 3.4 (2H,S), 3.8 (2H,m), 4.3 (2H,m), 7.7 (4H,m).
Procedure 2: A solution of 36.67 (0.192 mol) of 2-hydroxyethyl phthalimide, 29.99 g (0.211 mol) of 2,2,6-trimethyl-1,3-dioxen-4-one, and 0.2 g of p-toluenesulfonic acid in 200 ml of toluene was refluxed for 12 hours under nitrogen. The mixture was cooled to room temperature and washed with 10% sodium bicarbonate and brine. The organic phase was separated, dried over MgSO 4 , and concentrated in vacuo to give a crude oil which was subjected to flash chromatography (silica gel, 7:3 petroleum ether/ethyl acetate). The isolated solid was recrystallized from petroleum ether/ethyl acetate to yield 31.61 g (59.8%) of a white solid with m.p. and NMR data identical to the material prepared by Procedure 1.
C. 2,6-dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-methylphenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 7.0 g (0.25 mol) of 2-phthalimidoethyl acetoacetate and 3.1 g (0.025 mol) of methyl3-aminocrotonate in 150 ml of 2-propanol was refluxed for 15 hours under nitrogen. The solvent was removed in vacuo and the residue was subjected to flash chromatography (silica gel, 1:1 petroleum ether/ethyl acetate). The isolated product was recrystallized in dichloromethane/hexane to give 3.5 g (50%) of a pale yellow solid; m.p. 188°-190° C. NMR: (CDCl 3 ) δ 2.1 (9H,d), 3.5 (3M,s), 3.7 (2H,m), 4.2 (2H,m), 4.6 (1H,s), 5.8 (1H,s), 7.2 (8H,m).
EXAMPLE 2
2,6-dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 3.02 g (0.02 mol) of 3-nitrobenzaldehyde, 2.36 g (0.02 mol) of methyl-3-aminocrotonate, and 5.72 g (0.02 mol) of 2-phthalimidoethyl acetoacetate in 150 ml of 2-propanol was refluxed for 15 hours under nitrogen. The solvent was removed in vacuo, and the residue was subjected to flash chromatography (silica gel, 1:1 dichloromethane/hexane). The product was isolated and recrystallized from 1:1 dichloromethane/hexane to yield 3.0 g (30%) of a pale yellow solid; m.p. 181.5°-182.5° C. NMR: (CDCl 3 ); δ 2.3 (6H,s), 3.5 (3H,s), 3.9 (2H,m), 4.2 (2H,m), 4.9 (1H,s), 6.0 (1H,s), 7.0-8.0 (8H,m).
EXAMPLE 3
2-6-dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-trifluoromethylphenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 627 mg (3.6 m mol) of 3-trifluoromethyl benzaldehyde, 1.0 g (3.6 m mol) of 2-phthalimidoethyl acetoacetate, and 419 mg (3.6 m mol) of methyl 3-aminocrotonate in 50 ml of 2-propanol was refluxed for 15 hours under nitrogen. After removal of solvent in vacuo, the product was purified via preparative thin layer chromatography (silica gel, 1:1 ethyl acetate/petroleum ether) to yield 130 mg of a hygroscopic yellow solid. NMR: (CDCl 3 ) δ 2.2 (6H,t), 3.8 (5H,m), 4.2 (2H,m), 4.8 (1M,s), 6.5 (1H,s), 7.4 (8H,m).
EXAMPLE 4
2,6-dimethyl-3,5-di(2-phthalimidocarbethoxy)-4-(3-nitrophenyl)-1,4-dihydropyridine
A solution of 137 mg (0.9 m mol) of 3-nitrobenzaldehyde, 0.5 g (1.82 m mol) of 2-phthalimidoethyl acetoacetate, and 0.16 ml (2.4 m mol) of 14.7M ammonium hydroxide in 40 ml of 2-propanol was refluxed for 15 hours under nitrogen. The solvent was removed in vacuo and the residue was subjected to flash chromatography (silica gel, 3:1 petroleum ether/ethyl acetate) to yield 50 mg of pale yellow product; m.p. 92°-94° C.; NMR: (CDCl 3 ) δ 2.2 (6M,s), 3.8 (4H,m), 4.2 (4H,m), 4.8 (1H,s), 6.1 (1H,s), 7.2 (12H,m).
EXAMPLE 5
2,6-dimethyl-3-(3-phthalimidocarbopropoxy-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A. N-(3-hydroxypropyl)phthalimide
A solution of 18.95 g (0.25 mo.) of 3-aminopropanol and 37.0 g (0.25 mol) of phthalic anhydride in 25 ml of dry toluene was refluxed for three hours using a Dean-Stark apparatus. The mixture was cooled, concentrated in vacuo, dissolved in dichloromethane and washed with water. The evaporated organic phase was dried over magnesium sulfate, concentrated in vacuo, and distilled at 183°-184° C. (0.1 mm Hg) to give 28.18 g (55%) of a white solid; m.p. 75°-77° C.; NMR: (CDCl 3 ) δ 1.9 (2H,q), 3.65 (5H,m), 7.6 (4H,s).
B. 3-phthalimidopropyl acetoacetate
A solution of 22.8 g (0.111 mol) of N-3-hydroxypropyl phthalimide and 14.46 g (0.111 mol) of ethyl acetoacetate was heated at 145°-150° C. for 12 hours. Ethanol was removed with nitrogen flow during the course of the reaction. The mixture was cooled to room temperature, dissolved in dichloromethane, and washed with brine. The separated organic phase was dried over magnesium sulfate, concentrated in vacuo, and distilled at 211°-219° C. (0.125 mm Hg) to yield 17.3 g (54%) of a white solid; m.p. 67°-71° C. NMR: (CDCl 3 ) δ 2.0 (2H,m), 2.2 (3H,s), 3.3 (2H,s), 3.7 (2H,t), 4.05 (2M,t), 7.62 (4H,d).
C. 2,6-dimethyl-3-(3-phthalimidocarbopropoxy-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 7.0 g (0.24 mol) of phthalimidopropyl acetoacetate, 3.65 g (0.02 mol) of 3-nitrobenzaldehyde, and 2.79 g (0.02 mol) of methyl 3-aminocrotonate in 145 ml of 2-propanol was heated at 80° C. under nitrogen for 36 hours. On cooling to room temperature a pale yellow solid precipitated which was filtered and recrystallized from dichloromethane/petroleum ether. Yield 7.56 g (60%) m.p. 169°-172° C. NMR: (CDCl 3 ) w 1.95 (2H,m), 2.35 (6H,5), 3.6 (5H,m), 4.0 (2H,t), 5.0 (1H,s), 6.0 (1H,s), 7.55 (8H,m).
EXAMPLE 6
2,6-Dimethyl-3-(6-phthalimidocarbohexoxy)-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A. N-(6-hydroxyhexyl)phthalimide
A solution of 23.78 g (0.16 mol) of 6-aminohexanol in 190 ml of toluene was refluxed for 12 hours using a Dean-Stark apparatus. The mixture was cooled and concentrated in vacuo to a white solid. Recrystallization from dichloromethane/petroleum ether gave 28.04 g (70.42%) of product m.p. 51°-53° C. NMR: (CDCl 3 ) w 1.45 (8H, bs), 2.1 (1H, s), 3.55 (4H, m), 7.57 (4-H, m).
B. 6-phthalimidohexyl acetoacetate
A mixture of 22.1 g (0.09 mol) of N-(6-hydroxyhexyl) phthalimide and 10.2 g (0.08 mol) of ethyl acetoacetate was heated in an oil bath at 145° C. under nitrogen for 15 hours. After drying on high vacuum the residue was subjected to flash chromatography (silica gel, 7:3 petroleum ether/ether). The product was isolated as 12.9 g (75%) of a pale yellow oil b.p. 218°-226° C./0.15 mm. NMR: (CDCl 3 ) w 1.5 (8H, m), 2.21 (3H, s), 3.35 (2H, s), 3.55 (2H, m), 3.99 (2H, t), 7.5 (4H, m).
C. 2,6-Dimethyl-3-(6-phthalimidocarbohexoxy-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 7.0 g (0.02 mol) of N-(6-phthalimdohexyl acetoacetate), 3.2 g (0.02 mol) of 3-nitrobenzaldehyde and 2.4 g (0.02 mol) of methyl 3-aminocrotonate in 125 ml. of 2-propanol was refluxed for 24 hours under nitrogen. The solvent was removed in vacuo and the residue was subjected to flash chromatography (silica gel, 7:3 petroleum ether/ethyl acetate) to give a pale yellow solid. Recrystallization from methanol gave 4.9 g (55%) of the product m.p. 134°-140° C. NMR: CDCl 3 ) δ 1.45 (8H, bs), 2.85 (6H, s), 3.55 (5H, m), 4.3 (2H, t), 4.99 (1H, s), 6.3 (1H, s), 7.55 (8H, m).
EXAMPLE 7
2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A. N-(2hydroxyethyl)phthalimidine
A mixture of 15.9 g (0.26 mol) of 2-aminoethanol and 34.8 g (0.26 mol) of phthalide was heated at 190° C. for 6 hours using a Dean-Stark trap. The resultant known solid was subjected to flash chromatography (silica gel, dichloromethane) to yield 30 g (63%) of a white solid m.p. 119°-120° C., NMR: (CDCl 3 ) δ 3.6 (4H, m), 4.3 (2H, s), 4.4 (1H,s), 7.4 (4H, m).
B. N-(2-phthalimidino)ethyl acetoacetate
A mixture of 9.7 g (55 m mol) of N-(2-hydroxyethyl) phthalimidine, 14.2 g (0.11 mol) ethyl acetoacetate and 50 mg of sodium was heated in an oil bath at 140°-150° C. for 6 hours. The residual ethanol was removed under high vacuum and the resulting oil was subjected to flash chromatography (silica gel, 1:1 dichloromethane/petroleum ether) to give 5.0 g (35%) of an orange oil. NMR: (CDCl 3 ) δ 2.1 (3H, s), 3.3 (2H, s), 3.8 (2H, m) 4.3 (4H, m), 7.3 (4H, m)
C. 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 2.0 g (7.7 m mol) of N-(2-phthalimidino)ethyl acetoacetate, 1.16 g (7.7 m mol) of 3-nitrobenzaldehyde, and 0.89 g (7.7 m mol) of methyl 3-aminocrotonate in 50 ml of 2-propanol was heated at 80°-85° C. under nitrogen for 15 hours. The mixture was concentrated in vacuo and subjected to flash chromatography (silica gel, 1:1 petroleum ether/ethyl acetate) to yield 1.90 g of a pale yellow solid, m.p. 170°-175° C. NMR: (CDCl 3 ) δ 2.3 (6H, s), 3.5 (3H, s), 3.7 (2H, m), 4.1 (4H, m), 4.9 (1H, s), 6.8-7.9 (9H, m)
EXAMPLE 8
2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A. 2-(3-tolylsulfonyl)isoindoline
A solution of 34.2 g (0.2 mol) of p-toluenesulfonamide in 100 ml of dry N,N-dimethylformamide was added dropwise to a suspension of 18.9 g (0.42 mol) of sodium hydride (50% oil dispersion) in 60 ml of N,N-dimethylformamide. The reaction was stirred at room temperature for one hour, followed by one hour at 60° C. A solution of 52.8 g (0.2 mol) of α,α'-dibromo-O-xylene in 300 ml of N,N-dimethylformamide was added at such a rate that the temperature of the reaction mixture remained between 60°-70° C. After further stirring for 48 hours at room temperature under nitrogen ice water was added to the reaction mixture. The precipitated solid was filtered and recrystallized from hot ethanol. Yield 33.58 g, m.p. 175°-177° C. NMR (CDCl 3 ) δ 2.32 (3H, s), 4.5 (4H,s), 7.25 (8H, m)
B. Isoindoline
A solution of 12.0 g (0.044 mol) of 2-(p-tolylsulfonyl) isoindoline, 12.0 g (0.13 mol) of phenol, 90 ml of 48% HBr, and 15 ml (0.201 mol) of propionic acid was refluxed for two hours. The mixture was cooled to room temperature, triturated with diethyl ether, and then added to a solution of 75 gm of sodium hydroxide in 200 ml of cold water. This mixture was extracted with diethyl ether and the combined ether extracts were washed with water. The organic phase was dried over magnesium sulfate, concentrated in vacuo and kugelrohr distilled to give 3.28 g (61%) of a white solid, m.p. 118°-127° C. NMR (CDCl 3 ) δ 2.2 (1H,s), 4.0 (4H, s), 6.95 (4H, s)
C. 2-(2-hydroxyethyl) isoindoline
A solution of 2.85 g (0.0252 mol) of isoindoline, 2.99 g (0.0252 mol) of 2-bromoethanol and 5.09 g (0.05 mol) of triethylamine in 100 ml of dry toluene was refluxed for 12 hours. After cooling the mixture was filtered, concentrated in vacuo, dissolved in ethyl acetate and washed with water. The organic phase was dried over magnesium sulfate and concentrated in vacuo to yield 2.58 g (63%) of a dark red oil. NMR (CDCl 3 ) δ 2.78 (2H, t), 3.52 (2H, t), 3.82 (4H, s), 7.0 (4H, s)
D. (2-Isoindolinyl)ethyl acetoacetate
A solution of 4.67 g (0.029 mol) of 2-(2-hydroxyethyl) isoindoline and 3.72 g (0.029 mol) of ethyl acetoacetate was heated at 100°-110° C. under nitrogen for 36 hours. Ethanol was removed with nitrogen flow during the course of the reaction. The mixture was subjected to flash chromatography (silica gel, 1:1 ethylacetate/petroleum ether) to give 1.54 g (22%) of a dark oil. NMR (CDCl 3 ) δ 2.2 (3H, s), 2.94 (2H, t), 3.4 (2H, s), 3.9 (4H, s), 4.24 (2H, t), 7.04 (4H, s)
E. 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 1.54 g (6.2 m mol) of 2-isoindolinylethyl acetoacetate, 0.942 g (6.2 m mol) of 3-nitrobenzaldehyde and 0.717 g (6.2 m mol) of methyl 3-aminocrotonate in 37 ml of 2-propanol was heated at 80° C. under nitrogen for 48 hours. The crude mixture was concentrated in vacuo and subjected to flash chromatography (silica gel, 1:1 petroleum ether/ethyl acetate) to give 1.38 g (46%) of a brown solid, m.p. 63°-69° C. NMR (CDCl 3 ) δ 2.29 (6H, s), 2.8 (2H, t), 3.5 (2H, s), 3.8 (4H, s), 4.12 (2H, t), 5.0 (1H, s), 6.2 (1H, bs), 7.33 (8H, m).
EXAMPLE 9
2,6-Dimethyl-3-(2-succimimidocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A. N-(2-hydroxyethyl)succimimide
24.64 g (0.40 mol) of 2-aminoethanol was added dropwise under nitrogen to 40.0 g (0.4 mol) of succinic anhydride. After the addition, the reaction mixture was stirred for 10 minutes at room temperature, followed by 35 minutes at 105° C. The reaction mixture was cooled, triturated with diethyl ether, dried, concentrated and distilled at 183°-184° C./0.1 mm Hg to give 29.69 g (52%) of a white solid, m.p. 60°-62° C. NMR (CDCl 3 ) δ 2.65 (4H, s), 3.35 (1H, s), 3.6 (4H, s).
B. (2-succimimido)ethyl acetoacetate
A solution of 21.56 g (0.15 mol) of N-(2-hydroxyethyl) succinimide and 19.6 g (0.15 mol) of ethyl acetoacetate was heated at 145° C. under nitrogen for 12 hours. Ethanol was removed with nitrogen flow during the course of the reaction. The mixture was cooled, dissolved in dichloromethane and washed with water. The organic phase was dried over magnesium sulfate and concentrated in vacuo. Distillation of the residue (144°-155° C./0.1 mm) gave 15.72 g (46%) of a yellow oil. NMR (CDCl 3 ) δ 2.2 (3H, 2), 2.65 (4H, s), 3.32 (2H, s), 3.62 (2H, m), 4.2 (2H, m)
C. 2,6-Dimethyl-3-(2-succimimidocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 7.0 g (0.03 mol) of (2-succinimido)ethyl acetoacetate, 4.7 g (0.03 mol) of 3-nitrobenzaldehyde and 3.5 g (0.03 mol) of methyl 3-aminocrotonate in 100 ml of 2-propanol was refluxed under nitrogen for 15 hours. The mixture was concentrated, dried under high vacuum and then subjected to flash chromatography (silica gel, 1:1 ethyl acetate/petroleum ether) to give a pale yellow solid. Recrystallization from dichloromethane/petroleum ether yielded 4.5 g (32%) of the product, m.p. 184°-186° C. NMR (CDCl 3 ) δ 2.3 (6H, s), 2.6 (4H, s), 3.6 (5H, t), 4.1 (2H, m), 4.9 (1H, s), 6.1 (1H, s), 7.5 (4H, m)
EXAMPLE 10
2,6-Dimethyl-3-[2-(2-oxopyrrolidino)carbethoxy]-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A. 2-(2-oxopyrrolidino)ethyl acetoacetate
A mixture of 20 g (0.16 mol) of 1-hydroxyethyl-2-oxo-pyrrolidine, 40 g (0.31 mole) of ethyl acetoacetate and 100 mg of sodium was heated at 140°-150° C. for six hours. Residual ethanol was removed in vacuo and the resultant oil was kugelrohr distilled (200° C./1 mm) to give 1.38 g (40%) of the product. NMR (CDCl 3 ) δ 2.1 (7H, m), 3.4 (6H, m) 4.1 (2H, t)
B. 2,6-Dimethyl-3-[2-(2-oxopyrrolidino)carbethoxy]-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 4.0 g (0.019 mol) of 2-(2-oxopyrrolidino) ethyl acetoacetate, 7.8 g (0.019 mol) of 3-nitrobenzaldehyde and 2.2 g (0.019 mol) of methyl 3-aminocrotonate in 100 ml of 2-propanol was refluxed for 15 hours under nitrogen. The solvent was removed in vacuo and the residue was subjected to flash chromatography (silica gel, 9:1 petroleum ether/ethyl acetate) to give a yellow solid. Recrystallization from ethyl acetate/diethyl ether/petroleum ether gave 4.0 g of the product, m.p. 112°-114° C. NMR (CDCl 3 ) δ 2.3 (10H, s), 3.3 (4H, m), 3.5 (3H, s), 4.0 (2H, m), 5.0 (1H, s), 7.4 (5H, m)
EXAMPLE 11
2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A. 1-(2-hydroxyethyl)-2,5-dimethylpyrrole
A mixture of 20 g (0.33 mol) of 2-aminoethanol and 38 g (0.33 mol) of 2,5-hexanedione was stirred until the vigorous reaction subsided. 100 ml of toluene was added and the solution was refluxed to 15 hours in a Dean-Stark apparatus. The solvent was removed in vacuo and the resulting oil was kugelrohr distilled at 110° C./1.5 mm to yield 40 g (87%) of a white solid. NMR (CDCl 3 ) δ 2.1 (1H, s), 2.2 (6H, s), 3.7 (4H, m), 5.6 (2H, s)
B. 2-(2,5-dimethylpyrrolyl)ethyl acetoacetate
A mixture of 28 g (0.20 mol) of 1-(2-hydroxyethyl)-2,5-dimethylpyrrole and 31.2 g (0.24 mol) of ethyl acetoacetate was heated at 145° C. for six hours. Residual ethanol was removed in vacuo and kugelrohr distillation of the residue gave 27 g (61%) of pale green oil. NMR (CDCl 3 ) δ 2.1 (9H, s), 3.3 (2H, s), 4.0 (4H, m) 5.6 (2H, s)
C. 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine
A solution of 2.3 g (0.02 mol) of 2-(2,5-dimethylpyrrolyl) ethyl acetoacetate, 2.3 g (0.02 mol) of methyl 3-aminocrotonate and 3.39 g (0.02 mol) of 3-nitrobenzaldehyde in 100 ml of 2-propanol was refluxed for 15 hours under nitrogen. The solvent was removed in vacuo and the resulting solid was subjected to flash chromatography (silica gel, 8:1:1 petroleum ether/dichloromethane/ethyl acetate). The product was recrystallized from petroleum ether/dichloromethane/diethylether to give 3.5 g (39%) of an air- and light-sensitive solid, m.p. 156.5°-160° C. NMR (CDCl 3 ) δ2.1 (6H, s), 2.2 (3H, s), 2.3 (3H, s), 3.5 (3H, s), 3.9 (4H, m), 5.0 (1H, s), 5.6 (2H, s), 6.1 (1H, s), 7.8 (4H, m)
EXAMPLE 12
2,6-Dimethyl-3,5-(2,5-dimethylpyrrolylcarbethoxy)-4-(3-nitrophenyl)-1,4-dihydropyridine
A solution of 2.0 g (0.01 mol) of 2-(2,5-dimethylpyrrolyl) ethyl acetoacetate, 0.73 g (0.005 mol) of 3-nitrobenzaldehyde and 0.48 ml of concentrated ammonium hydroxide in 6 ml of absolute ethanol was refluxed under nitrogen for six hours and then stirred overnight at room temperature. The solvent was removed in vacuo and the resulting solid was purified by flash chromatography on silica (8:2 petroleum ether/ethyl acetate). The product was recrystallized from methylene chloride/methanol to give 0.62 g of a deep yellow powder, m.p. 167°-170° C. NMR (CDCl 3 ) δ: 2.1 (12H, s) 2.23 (6H, s), 3.91 (8H, m), 4.9 (1H, s), 5.58 (5H, s), 7.1 (2H, m) and 7.8 (2H, m)
EXAMPLE 13
The general procedure of Example 2 is repeated, except that the 3-nitrobenzaldehyde utilized therein is replaced in successive runs by an equimolar amount of
(a) 2-nitrobenzaldehyde,
(b) 2-chlorobenzaldehyde,
(c) 3-chlorobenzaldehyde
(d) 3-cyanobenzaldehyde,
(e) 3-methoxybenzaldehyde,
(f) 2-bromobenzaldehyde,
(g) 2-chloro-6-fluorobenzaldehyde,
(h) 2-chloro-5-nitrobenzaldehyde,
(i) 3-bromobenzaldehyde,
(j) 2,6-dinitrobenzaldehyde,
(k) 2-chloro-6-nitrobenzaldehyde,
(l) 2-fluorobenzaldehyde,
(m) 3-fluorobenzaldehyde,
(n) 2-nitro-5-chlorobenzaldehyde,
(o) 5-bromo-2-furaldehyde,
(p) 2-furaldehyde,
(q) indole-3-carboxaldehyde,
(r) 5-nitro-2-furaldehyde,
(s) 2-pyridinecarboxaldehyde,
(t) 3-pyridinecarboxaldehyde,
(u) 2-thiophenecarboxaldehyde,
(v) 3-thiophenecarboxaldehyde
(w) 3-quinolinecarboxaldehyde,
(x) pyrrole-2-carboxaldehyde, and
(y) 1-methylpyrrole-2-carboxaldehyde,
to produce respectively,
(a) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(b) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(c) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(d) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-cyanophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(e) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-methoxy-phenyl)-5-carbomethoxy-1,4-dihydropyridine,
(f) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-bromophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(g) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-chloro-6-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(h) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-chloro-5-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(i) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-bromophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(j) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2,6-dinitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(k) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-chloro-6-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(l) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine
(m) 2,6-dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(n) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-nitro-5-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine
(o) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(5-bromo-2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(p) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(q) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-indolyl)-5-carbomethoxy-1,4-dihydropyridine,
(r) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(5-nitro-2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(s) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-pyridyl)-5-carbomethoxy-1,4-dihydropyridine,
(t) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-pyridyl)-5-carbomethoxy-1,4-dihydropyridine,
(u) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-thienyl)-5-carbomethoxy-1,4-dihydropyridine,
(v) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-thienyl)-5-carbomethoxy-1,4-dihydropyridine,
(w) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(3-quinolinyl)-5-carbomethoxy-1,4-dihydropyridine,
(x) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(2-pyrrolyl)-5-carbomethoxy-1,4-dihydropyridine and
(y) 2,6-Dimethyl-3-(2-phthalimidocarbethoxy)-4-(1-methyl-2-pyrrolyl)-5-carbomethoxy-1,4-dihydropyridine.
EXAMPLE 14
The general procedure of Examples 1C, 2, 3, 5C, 6C, 7C, 8E, 9C, 10B and 11C are individually repeated except that the methyl-3-aminocrotonate utilized therein is replaced by an equimolar amount of ethyl 3-amino-4,4,4-trifluorocrotonate and there is thereby produced
(a) 2-methyl-3-(2-phthalimidocarbethoxy)-4-(3-methylphenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine,
(b) 2-methyl-3-(2-phthalimidocarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine,
(c) 2-methyl-3-(2-phthalimidocarbethoxy)-4-(3-trifluoromethylphenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine,
(d) 2-methyl-3-(3-phthalimidocarbopropoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine,
(e) 2-methyl-3-(6-phthalimidocarbohexoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine,
(f) 2-methyl-3-(2-phthalimidinocarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine,
(g) 2-methyl-3-(2-isoindolinylcarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine,
(h) 2-methyl-3-(2-succinimidocarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine,
(i) 2-methyl-3-[2-(2-oxopyrrolidino)carbethoxy]-4-(3-nitrophenyl)-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine, and
(j) 2-methyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-nitrophenyl-5-carbethoxy-6-trifluoromethyl-1,4-dihydropyridine, respectively.
EXAMPLE 15
The general procedures of Examples 1C, 2, 3, 5C, 6C, 7C, 8E, 9C, 10B and 11C are repeated except that the methyl 3-aminocrotonate utilized therein is replaced by an equimolar amount of ethyl 3-amino-5-dimethylamino-2-pentenoate in each instance, and there is thereby produced:
(a) 2-methyl-3-(2-phthalimidocarbethoxy)-4-(3-methylphenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(b) 2-methyl-3-(2-phthalimidocarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(c) 2-methyl-3-(2-phthalimidocarbethoxy)-4-(3-trifluoromethylphenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(d) 2-methyl-3-(3-phthalimidocarbopropoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(e) 2-methyl-3-(6-phthalimidocarbohexoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(f) 2-methyl-3-(2-phthalimidinocarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(g) 2-methyl-3-(2-isoindolinylcarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(h) 2-methyl-3-(2-succinimidocarbethoxy)-4-(3-nitrophenyl)-5-carboethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(i) 2-methyl-3-[2-(2-oxopyrrolidino)carbethoxy]-4-(3-nitrophenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine,
(j) 2-methyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-nitrophenyl)-5-carbethoxy-6-(2-dimethylaminoethyl)-1,4-dihydropyridine, respectively.
EXAMPLE 16
A. 2-phthalimidoethyl-4,4,4-trifluoroacetoacetate
The general procedure of Example 1B (procedure 1) is repeated except that the ethyl acetoacetate is replaced by an equimolar amount of 4,4,4-trifluoroacetaoacetate and there is thereby produced
(a) 2-phthalimidoethyl-4,4,4-trifluoroacetoacetate.
Similarly, the general procedures of Example 5B, 6B, 7B, 8D, 9B, 10A and 11B are each repeated as above except that the ethyl acetoacetate is replaced by an equimolar amount of 4,4,4-trifluoroacetoacetate and there are thereby produced.
(b) 3-phthalimidopropyl-4,4,4-trifluoroacetoacetate,
(c) 6-phthalimidohexyl-4,4,4-trifluroacetoacetate,
(d) N-2-phthalimidinoethyl-4,4,4-trifluroacetoacetate,
(e) 2-isoindolinylethyl-4,4,4-trifluroacetoacetate,
(f) 2-succinimidoethyl-4,4,4-trifluroacetoacetate,
(g) 2-(2-oxopyrrolidino)ethyl-4,4,4-trifluroacetoacetate, and
(h) 2-(2,5-dimethylpyrrolyl)ethyl-4,4,4-trifluroacetoacetate, respectively.
B. 2-trifluoromethyl-3-(2-phthalimidocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine.
The general procedure of Example 2 is repeated except that the 2-phthalimidoethylacetoacetate utilized there is replaced by an equimolar amount of 2-phthalimidoethyl-4,4,4-trifluroacetoacetate, and there is thereby produced
(a) 2-trifluoromethyl-3-(2-phthalimidocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine.
Similarly, utilizing the seven 4,4,4-trifluroacetoacetate, derivatives mentioned under Example 16A and repeating the general procedure of Example 2, there are produced
(b) 2-trifluoromethyl-3-(3-phthalimidocarbopropoxy)-4-(3-nitro-phenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine,
(c) 2-trifluoromethyl-3-(6-phthalimidocarbohexoxy)-4-(3-nitrophenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine,
(d) 2-trifluoromethyl-3-(2-phthalimidinocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine,
(e) 2-trifluoromethyl-3-(2-isoindolinylcarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine,
(f) 2-trifluoromethyl-3-(2-succinimidocarbethoxy)-4-(3-nitrophenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine,
(g) 2-trifluoromethyl-3-[2-(2-oxopyrrolidino)carbethoxy]-4-(3-nitrophenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine, and
(h) 2-trifluoromethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-nitrophenyl)-5-carbomethoxy-6-methyl-1,4-dihydropyridine, respectively.
EXAMPLE 17
The general procedure of Example 2 is repeated except that methyl-3-aminocrotonate and 2-phthalimidoethyl acetoacetate are replaced by equimolar amounts of Ethyl 3-amino-4,4,4-trifluorocrotonate and 2-phthalimidoethyl-4,4,4-trifluoroacetoacetate, and there is thereby produced
(a) 2,6-di-trifluoromethyl-3-(2-phthalimidocarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-1,4-dihydropyridine.
Similarly, utilizing equimolar amounts of the seven 4,4,4-trifluoroacetoacetate derivatives mentioned under Example 16A in place of 2-phthalimidoethyl-4,4,4-trifluoroacetoacetate, there are thereby produced, respectively:
(b) 2,6-di-trifluoromethyl-3-(2-phthalimidocarbopropoxy)-4-(3-nitrophenyl)-5-carbethoxy-1,4-dihydropyridine,
(c) 2,6-di-trifluoromethyl-3-(2-phthalimidocabohexoxy)-4-(3-nitrophenyl)-5-carbethoxy-1,4-dihydropyridine,
(d) 2,6-di-trifluoromethyl-3-(2-phthalimidinocarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-1,4-dihydropyridine,
(e) 2,6-di-trifluoromethyl-3-(2-isoindolinylcarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-1,4-dihydropyridine,
(f) 2,6-di-trifluoromethyl-3-(2-succinimidocarbethoxy)-4-(3-nitrophenyl)-5-carbethoxy-1,4-dihydropyridine,
(g) 2,6-di-trifluoromethyl-3-[2-(2-oxopyrrolidino)carbethoxy]-4-(3-nitrophenyl)-5-carbethoxy-1,4-dihydropyridine, and
(h) 2,6-di-trifluoromethyl-3-[2-(2,5-dimethylpyrrolyl)carb-ethoxy]-4-(3-nitrophenyl)-5-carbethoxy-1,4-dihydropyridine.
EXAMPLE 18
The general procedure of Example 4 is repeated except that the 2-phthalimidoethyl acetoacetate is replaced by an equimolar amount of 2-phthalimidoethyl-4,4,4-trifluoroacetoacetate and there is thereby produced
(a) 2,6-di-trifluoromethyl-3,5-di-(2-phthalimidocarbethoxy)-4-(3-nitrophenyl)-1,4-dihydropyridine.
Similarly, utilizing equimolar amounts of the seven 4,4,4-trifluoroacetoacetate derivatives mentioned under Example 16A in place of 2-phthalimidoethyl-4,4,4-trifluoroacetoacetate are thereby produced, respectively.
(b) 2,6-di-trifluoromethyl-3,5-di-(2-phthalimidocarbopropoxy)-4-(3-nitrophenyl)1,4-dihydropyridine,
(c) 2,6-di-trifluoromethyl-3,5-di-(2-phthalimidocarbohexoxy)-4-(3-nitrophenyl)-1,4-dihydropyridine,
(d) 2,6-di-trifluoromethyl-3,5-di-(2-phthalimidinocarbethoxy)-4-(3-nitrophenyl)-1,4-dihydropyridine,
(e) 2,6-di-trifluoromethyl-3,5-di-(2-isoindolinylcarbethoxy)-4-(3-nitrophenyl)-1,4-dihydropyridine,
(f) 2,6-di-trifluoromethyl-3,5-di-(2-succinimidocarbethoxy)-4-(3-nitrophenyl)-1,4-dihydropyridine,
(g) 2,6-di-trifluoromethyl-3,5-di-[2-(2-oxopyrrolidino)carbethoxy]-4-(3-nitrophenyl)-1,4-dihydropyridine, and
(h) 2,6-di-trifluoromethyl-3,5-di-[(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-nitrophenyl)-1,4-dihydropyridine.
EXAMPLE 19
The general procedure of Example 7C is repeated, except that the 3-nitrobenzaldehyde utilized therein is replaced, successively, with an equimolar amount of each of the 25 aldehydes listed in Example 13 to produce, respectively:
(a) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(b) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(c) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(d) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-cyanophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(e) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-methoxy-phenyl)-5-carbomethoxy-1,4-dihydropyridine,
(f) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-bromophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(g) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-chloro-6-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(h) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-chloro-5-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(i) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-bromophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(j) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2,6-dinitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(k) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-chloro-6-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(l) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(m) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(n) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-nitro-5-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine
(o) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(5-bromo-2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(p) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(q) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-indolyl)-5-carbomethoxy-1,4-dihydropyridine,
(r) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(5-nitro-2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(s) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-pyridyl)-5-carbomethoxy-1,4-dihydropyridine,
(t) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-pyridyl)-5-carbomethoxy-1,4-dihydropyridine,
(u) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-thienyl)-5-carbomethoxy-1,4-dihydropyridine,
(v) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-thienyl)-5-carbomethoxy-1,4-dihydropyridine,
(w) 2,6-dimethyl-3-(2-phthalimidinocarbethoxy)-4-(3-quinolinyl)-5-carbomethoxy-1,4-dihydropyridine,
(x) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(2-pyrrolyl)-5-carbomethoxy-1,4-dihydropyridine and
(y) 2,6-Dimethyl-3-(2-phthalimidinocarbethoxy)-4-(1-methyl-2-pyrrolyl)-5-carbomethoxy-1,4-dihydropyridine.
EXAMPLE 20
The general procedure of Example 8E is repeated, except that the 3-nitrobenzaldehyde used therein is replaced, successively, with an equimolar amount of each of the 25 aldehydes listed in Example 13 to produce, respectively:
(a) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4(2-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(b) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(c) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(d) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-cyanophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(e) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-methoxy-phenyl)-5-carbomethoxy-1,4-dihydropyridine,
(f) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-bromophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(g) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-chloro-6-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(h) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-chloro-5-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(i) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-bromophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(j) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2,6-dinitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(k) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-chloro-6-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(l) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine
(m) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(n) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-nitro-5-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine
(o) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(5-bromo-2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(p) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(q) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-indolyl)-5-carbomethoxy-1,4-dihydropyridine,
(r) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(5-nitro-2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(s) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-pyridyl)-5-carbomethoxy-1,4-dihydropyridine,
(t) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-pyridyl)-5-carbomethoxy-1,4-dihydropyridine,
(u) 2,6-Dimethyl-3-(2-isodinolinylcarbethoxy)-4-(2-thienyl)-5-carbomethoxy-1,4-dihydropyridine,
(v) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-thienyl)-5-carbomethoxy-1,4-dihydropyridine,
(w) 2,6-dimethyl-3-(2-isoindolinylcarbethoxy)-4-(3-quinolinyl)-5-carbomethoxy-1,4-dihydropyridine,
(x) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(2-pyrrolyl)-5-carbomethoxy-1,4-dihydropyridine and
(y) 2,6-Dimethyl-3-(2-isoindolinylcarbethoxy)-4-(1-methyl-2-pyrrolyl)-5-carbomethoxy-1,4-dihydropyridine.
EXAMPLE 21
The general procedure of Example 11C is repeated, except that the 3-nitrobenzaldehyde used therein is replaced, successively, with an equimolar amount of each of the 25 aldehydes listed in Example 13 to produce, respectively:
(a) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(b) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(c) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(d) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-cyanophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(e) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-methoxy-phenyl)-5-carbomethoxy-1,4-dihydropyridine,
(f) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-bromophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(g) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-chloro-6-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(h) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-chloro-5-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(i) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-bromophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(j) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2,6-dinitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(k) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-chloro-6-nitrophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(l) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine
(m) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-fluorophenyl)-5-carbomethoxy-1,4-dihydropyridine,
(n) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-nitro-5-chlorophenyl)-5-carbomethoxy-1,4-dihydropyridine
(o) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(5-bromo-2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(p) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(q) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-indolyl)-5-carbomethoxy-1,4-dihydropyridine,
(r) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(5-nitro-2-furyl)-5-carbomethoxy-1,4-dihydropyridine,
(s) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-pyridyl)-5-carbomethoxy-1,4-dihydropyridine,
(t) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-pyridyl)-5-carbomethoxy-1,4-dihydropyridine,
(u) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-thienyl)-5-carbomethoxy-1,4-dihydropyridine,
(v) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-thienyl)-5-carbomethoxy-1,4-dihydropyridine,
(w) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(3-quinolinyl)-5-carbomethoxy-1,4-dihydropyridine,
(x) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(2-pyrrolyl)-5-carbomethoxy-1,4-dihydropyridine and
(y) 2,6-Dimethyl-3-[2-(2,5-dimethylpyrrolyl)carbethoxy]-4-(1-methyl-2-pyrrolyl)-5-carbomethoxy-1,4-dihydropyridine.
PHARMACOLOGY
A. Binding Assay for Drugs Acting at the DHP Site of the Calcuim Channel.
The assay was carried out as described by Fairhurst et al., Life Sciences, 32, 1331 (1983). Washed rabbit skeletal muscle membranes (fraction 2-8X) were incubated for 30 minutes at 25° C. in 2 ml final volume of medium containing 12.5 mM HEPES buffer pH 7.4 and 0.5×10 -9 M 3 H-nitrendipine having a specific activity of approximately 17 Ci/m mol.
Parallel experiments contained, additionally, unlabelled nifedipine at a final concentration of 10 -6 M, to give the non-specific binding values.
The incubation tubes were rapidly chilled in ice and the contents filtered through Whatman GF/B filters on a Millipore manifold, and the filters washed with 2×10 ml ice-cold HEPES buffer. The filters were placed in scintillation counting vials with 8 ml of Cytoscint cocktail, disrupted mechanically by shaking for 30 minutes and counted.
Specific binding was determined by subtracting the radioactivity in the presence of nifedipine from that in the absence. Drugs which interact at the DHP site will reduce this specific binding in a dose-dependent manner. The assays for the compounds of this invention were made with logarithmically spaced concentrations, the data were plotted on a probit-concentration plot, and the IC 50 read off. The K I of the drug was calculated by standard techniques. The results of the assay are shown in Table I.
TABLE I*__________________________________________________________________________Ex. No. R.sub.3 AR.sub.4 R.sub.6 K.sub.I (moles)__________________________________________________________________________1. CH.sub.3 ##STR16## ##STR17## 1.97 × 10.sup.-82. CH.sub.3 ##STR18## ##STR19## .sup. 7 × 10.sup.-10 23. CH.sub.3 ##STR20## ##STR21## 4.8 × 10.sup.-8 ##STR22## ##STR23## ##STR24## 2.5 × 10.sup.-95. CH.sub.3 ##STR25## ##STR26## 4.8 × 10.sup.-96. CH.sub.3 ##STR27## ##STR28## 1.9 × 10.sup.-97. CH.sub.3 ##STR29## ##STR30## 2 × 10.sup.-88. CH.sub.3 ##STR31## ##STR32## 3.5 × 10.sup.-99. CH.sub.3 ##STR33## ##STR34## 1.5 × 10.sup.-710. CH.sub.3 ##STR35## ##STR36## 2.7 × 10.sup.-711. CH.sub.3 ##STR37## ##STR38## 2.5 × 10.sup.-9 ##STR39## ##STR40## ##STR41## 2.5 × 10.sup.-9Nifedipine CH.sub.3 CH.sub.3 ##STR42## 7.6 × 10.sup.-9Nicardipine CH.sub.3 ##STR43## ##STR44## 1.1 × 10.sup.-9__________________________________________________________________________ *For examples given, R.sub.1 = R.sub.2 = CH.sub.3
B. Hypotensive Activity:
Systolic arterial blood pressure was measured with the indirect tail cuff method in spontaneous hypertensive rates (SHR). The change in baseline pressure (170-210 mm Hg) was recorded at various time points following oral administration of 10 m mol/Kg of the test compound in polyethylene glycol. The results are given in Table II.
TABLE II______________________________________Hypotensive Effect (Oral Administration) Mean Change in Blood Pressure (Pressure before Administration minus pressure after Administration mm Hg)Test No. of 10 20 30 60 90 120Compound Animals min min min min min min______________________________________Compound 3 17 10 4 -2 5 -4of Ex. 1Compound 2 9 10 10 6 0 0of Ex. 2Compound 3 9 8 14 11 14 10of Ex. 4Compound 2 -5 -14 -10 -6 -6 -5of Ex. 5Compound 2 18 10 12 14 2 0of Ex. 6Compound 2 14 19 10 10 20 19of Ex. 7Compound 3 36 30 32 16 4 2of Ex. 8Compound 3 36 10 5 3 19 11of Ex. 9Compound 2 -17 -5 11 7 6 7of Ex. 10Compound 3 36 40 39 29 29 20of Ex. 11Nifedipine 6 37 36 20 15 4 4______________________________________
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Compounds having calcium channel antagonist activity of the formula: ##STR1## wherein R 1 and R 2 are each independently amino, trifluoromethyl, pentafluoroethyl, alkoxy, lower alkenyl, or lower alkynyl or branched or unbranched lower alkyl, which is unsubstituted or is substituted with cyano, hydroxy, acyloxy, hydrazino, lower alkyl amino, or di(lower alkyl)-amino or 5 or 6 membered saturated nitrogen-containing heterocyclic-1-yl, which is unsubstituted or is substituted with oxo, hydroxy, alkyl, and hydroxy (lower alkyl) R 3 is straight- or branched-chain C 1 to C 12 alkyl, alkenyl, alkynyl, or cycloalkyl, and is either unsubstituted or substituted with hydroxy, acyloxy, cyano, di(lower alkyl) amino 5- or 6-membered saturated nitrogen-containing heterocyclic -1-yl or R 3 is --A--R 4 , A is a straight- or branched-chain hydrocarbon moiety containing from 2 to 12 carbon atoms and from 0 to 2 double bonds, R 4 is selected from the group consisting of: ##STR2## R 5 is hydrogen, nitro, cyano, azido, amino, trifluoromethyl, alkylamino, dialkylamino, halo, carboxyl, carbalkoxy, alkyl, alkenyl, alkynyl, cycloalkyl, acylamino, carboxamido, sulfonamido, and SO m -(lower)alkyl where m is 0, 1, or 2 and R 6 is aryl or heteroaryl or a pharmaceutically-acceptable salt thereof are disclosed. Also disclosed is a method of treating hypertension and other disorders by administering an effective amount of a compound of the present invention.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of patent application Ser. No. 12/777,163, filed May 10, 2010, which claims the benefit of Provisional Application No. 61/177,203, filed May 11, 2009, the entire disclosures of which are hereby incorporated by reference herein.
BACKGROUND
Hitch assemblies provide a connection between a device, such as a trailer, ski rack, or the like, and a vehicle. A receiver-type hitch assembly typically includes a receiver that is attached to the frame of a vehicle and a hitch that is removably inserted into the receiver. The hitch may include, for example, a conventional trailer ball that is sized to be engaged by a ball receiver on a trailer. Alternatively, the hitch may comprise a portion of a carrier, for example, a bicycle carrier, ski carrier, cargo carrier, or the like. The hitch may include additional or alternative mechanisms for engaging an apparatus to be carried or towed. A conventional SAE receiver typically comprises a rectangular tube with a rearwardly facing square opening that is 1.25 inches (32 mm), 2.0 inches (51 mm) or 2.5 inches (64 mm) square.
The insertable hitch includes a shaft having an outer dimension that is somewhat smaller than the inner dimension of the receiver so that the hitch can be relatively easily inserted into the receiver. A hitch pin (or locking pin) is inserted through holes provided in the side walls of the receiver and alignable holes in the hitch. The locking pin may be secured, for example, with a retaining clip to prevent the locking pin from inadvertently coming out during use. Exemplary prior art hitch assemblies include those disclosed in U.S. Pat. No. 6,105,989, to Linger, which is hereby incorporated by reference in its entirety, and in U.S. Pat. No. 6,382,656, to Johnson, Jr., which is hereby incorporated by reference in its entirety.
Detachable hitches are preferred for many applications. For example, a user may use one hitch for towing loads and other hitches for attaching bicycle racks, ski racks, carriers, or the like, to the vehicle. Also, hitches typically extend beyond the rear of the towing vehicle to enable attachment of a trailer to the hitch with clearance for the trailer and towing vehicle to articulate relative to each other during towing. The protruding hitch with a ball attachment can be bothersome and dangerous when the vehicle is used without the trailer attached; therefore, it is beneficial to be able to remove the hitch when it is not needed.
However, as noted above the hitch shaft is smaller than the receiver opening, and so the fit between the hitch and the receiver includes some play between the receiver and the walls of the hitch shaft. The relatively loose fit permits undesirable relative movement or play between the receiver and the hitch, which can be noisy and annoying. The play between the walls of the receiver and hitch can cause clanging noises and vibrations that can be felt by operators and passengers within the towing vehicle. The play may also be magnified by the lever arm of the hitch so that it is felt more strongly by the trailer. That same play can also increase wear and stress on various parts of the mechanisms attaching the trailer to the towing vehicle, leading to undesirable wear and fatigue.
The disadvantages of the relatively loose fit between the receiver and hitch coupling have been recognized by others. For example, in U.S. Pat. No. 6,974,147, to Kolda, which is hereby incorporated by reference, a mechanism for preventing relative movement between these members is disclosed, wherein the tow bar or mounting member is provided with a cam that is adjustably urged into the mounting member and abuts the hitch pin. The adjustment mechanism causes the cam to rotate, extending through a slot in the mounting member, and is urged against the receiver. However, the mechanism has the disadvantage that it presses against the receiver at a single position and against the opposite side of the mounting member at a single position, in addition to the hitch pin, which may still permit some movement between the mounting member and receiver.
SUMMARY
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 of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
An anti-rattle hitch is disclosed having an insert that is configured to be inserted into a receiver. For clarity, the hitch will be described with directional references, such as “upper” and “lower,” although it will be appreciated that the particular orientation may be different. The insert has an upper wall with a piston aperture, a lower wall, and two side walls. A lower wedge block and an upper wedge block are disposed in the insert. The lower wedge block has a lower surface that slidably engages the lower wall of the insert, and an upper angled surface. The upper wedge block has a lower angled surface that slidably engages the lower wedge block, and a piston that extends through the piston aperture, such that the longitudinal position of the upper wedge block is constrained by the piston. An adjustment member engages the lower wedge block, extends out of the insert, and is operable to adjust the longitudinal position of the lower wedge block, thereby adjusting the transverse position of the upper wedge block. This configuration allows adjusting the position of the piston that extends out of the insert. The hitch is configured such that the piston may be adjusted to press against the receiver, thereby locking the hitch therein and avoiding play therebetween.
In an embodiment of the invention, the piston comprises a cylinder that is attached to the upper wedge member with a screw.
In an embodiment of the invention, a second piston aperture is provided through the insert, and a second piston is attached to the upper wedge block and extends through the second piston aperture.
In an embodiment of the invention, the hitch includes a ball mount member that is configured to support a tow ball.
In an embodiment of the invention, the adjustment member is a threaded rod that threadably engages the first wedge member and a head that extends out of the tubular insert.
In an embodiment of the invention, the adjustment member includes a security feature, such as a lock or a keyed head, that hinders operation of the adjustment member without a corresponding tool.
In an embodiment of the invention, a low friction panel is provided between the angled faces and may comprise an ultrahigh molecular weight polyethylene.
In an embodiment of the invention, the wedge blocks further include second angled faces that are slidably engaged.
DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1A is a perspective view of a hitch assembly in accordance with the present invention;
FIG. 1B is another perspective view of the hitch shown in FIG. 1A ;
FIG. 2 is an exploded view of the hitch assembly shown in FIG. 1A ; and
FIG. 3 is a cross-sectional view of the hitch assembly shown in FIG. 1A .
FIG. 4 is a fragmentary end view of the hitch shown in FIG. 1A .
DETAILED DESCRIPTION
FIG. 1A is a perspective view of a hitch assembly 100 in accordance with the present invention and showing in phantom a receiver 90 and a tow ball 101 . A three-quarter rear perspective view of the hitch assembly 100 is shown in FIG. 1B . The hitch assembly 100 includes a tubular insert 102 that is sized and configured to be inserted into a receiver 90 to cooperatively comprise a receiver-type hitch assembly. The tubular insert 102 is a substantially square tube. In an exemplary embodiment the tubular insert 102 is sized to engage an SAE standard receiver having a square opening that is 1.25 inches (32 mm), 2.0 inches (51 mm) or 2.5 inches (64 mm) on each side. The tubular insert 102 is fixedly attached to a structural member, for example a ball mount 103 that is configured to support a tow ball 101 . For example, the tow ball 101 ( FIG. 1A ) may bolt through aperture 107 ( FIG. 1B ) in the ball mount 103 . An optional gusset plate 105 reinforces the connection between the tubular insert 102 and the ball mount 103
The tubular insert 102 includes a first wall 102 A (in this case the upper wall), oppositely disposed second and third walls 102 B, 102 C (e.g., side walls), and a fourth wall 102 D (e.g., lower wall) disposed opposite the first wall 102 A. As seen most clearly in the exploded view of FIG. 2 , the first wall 102 A includes a pair of longitudinally spaced piston apertures 104 . The second and third walls 102 B, 102 C each have a locking pin aperture 106 (one visible), which are aligned to receive a conventional locking pin (not shown). Corresponding locking pin apertures 96 are provided through the receiver 90 . Also visible in FIG. 1A are a pair of adjustable pistons 110 , which are discussed in more detail below.
FIG. 2 shows an exploded view of the hitch 100 . Refer also to FIG. 3 , which shows a longitudinal cross-sectional view of the hitch 100 , taken through a centerline of the tubular member 102 . A sliding wedge mechanism is disposed in the tubular insert 102 and is operable to selectively tighten the hitch 100 within the receiver 90 , thereby reducing or eliminating play between the hitch 100 and the receiver 90 . The wedge mechanism includes a first wedge member 112 , defining a first angled face 112 A, a second angled face 112 B and a recess 112 C therebetween. A threaded aperture 113 is oriented longitudinally from a proximal end of the first wedge member 112 .
A second wedge member 114 is positioned generally adjacent the first wedge member 112 and includes a first angled face 114 A, a second angled face 114 B, and a recess 114 C therebetween. When assembled, the first wedge member first angled face 112 A is disposed adjacent the second wedge member first angled face 114 A, and the first wedge member second angled face 112 B is disposed adjacent the second wedge member second angled face 114 B to slidably engage the first wedge member 112 when the hitch 100 is assembled.
The pistons 110 are attached to an upper face 114 D of the upper block 114 . In the present embodiment the attachment is accomplished with flathead fasteners 110 A, although other attachment means may be used, including for example by forming a post (threaded or unthreaded) on the bottom of the pistons, with corresponding apertures in the second wedge member 114 . Optionally, recesses 114 E are provided in which the pistons 110 are securely seated.
A threaded adjustment fastener 120 extends through an aperture 108 in the ball mount 103 and into the tubular insert 102 to threadably engage the first wedge member 112 threaded aperture 113 . Optionally, an angled spacer 122 and spring, or other biasing member 124 , are also provided. It will now be appreciated that the longitudinal position of the second wedge member 114 is constrained within the tubular insert 102 by the pistons 110 extending through the piston apertures 104 . The position of the first wedge member 112 is adjusted with the adjustable fastener 120 .
The first and second wedge members 112 , 114 angled faces 112 A, 114 A, and 112 B, 114 B are configured to slidably engage. In this embodiment, low friction pads 118 are provided between the respective angled faces. For example, low friction pads may comprise polymeric material. In a current embodiment, the low friction pads comprise ultrahigh molecular weight polyethylene, which has a very low coefficient of friction, is self-lubricating, and is highly resistant to abrasion.
The wedge member recesses 112 C, 114 C are sized and shaped to cooperatively define an opening therebetween that is aligned with the locking pin apertures 106 in the tubular insert 102 (which are also alignable with corresponding apertures 96 in the receiver 90 ), such that the wedge members 112 , 114 will not interfere with the locking pin during use.
A fragmentary end view of the hitch 100 is shown in FIG. 4 , showing the first wedge member 112 and the lower portion of the tubular insert 102 . In this embodiment, the lower surface of the first wedge member 112 is provided with longitudinal ribs 112 D to reduce friction between the first wedge member 112 and the tubular member 102 , and thereby facilitate adjustment of the wedge mechanism. It is further contemplated that a low friction panel or other friction-reducing mechanism (not shown) may be provided between the first wedge member 112 and the tubular insert 102 .
In the present embodiment, the hitch 100 is assembled by inserting the adjustment member 120 through the aperture 108 in the ball mount 103 and inserting the angled spacer 122 and spring 124 through the open end of the tubular insert 102 to slide over the adjustment member 120 . The first and second wedge members 112 , 114 are inserted together into the tubular insert 102 and the adjustment member 120 engages the threaded aperture 113 . The second wedge member is then positioned such that the recesses 114 E are aligned with the piston apertures 104 , and the pistons 110 are inserted through the respective piston apertures 104 and attached to the second wedge member 114 .
To use the hitch 100 , the adjustment member 120 is adjusted such that the pistons 100 are approximately flush with the first wall 102 A of the tubular insert 102 . The hitch 100 may then be inserted into the receiver 90 . The adjustment member 114 is then adjusted such that the first wedge member 112 is drawn to the right in FIG. 3 , as indicated by arrow 80 . The second wedge member 114 is restrained from moving longitudinally by the pistons 110 . Due to the angled faced of the first and second wedge members 112 , 114 , the second wedge member 114 moves upwardly as indicated by arrow 81 , such that the pistons 110 move upwardly to engage and press against the receiver 90 , as indicated by arrows 82 . The locking pin (not shown) is then inserted through the locking pin apertures 96 , 106 .
To disengage the hitch 100 from the receiver 90 , the adjustment member 120 is adjusted in the reverse direction. After removing the locking pin, the adjustment member 120 is adjusted in the opposite direction. The biasing spring 124 aids in moving the first wedge member to the left in FIG. 3 , and the pistons 110 disengage from the receiver 90 , such that the tubular insert 102 can be readily pulled out of the receiver 90 .
It is also contemplated that the adjustment member 120 may include one or more security features, such as a lock or the like. In an embodiment the adjustment member incorporates an unusual head shape, such that the adjustment member is not easily adjusted without a corresponding, suitably keyed tool (not shown). This security feature provides the additional advantage that once the hitch 100 is securely locked to the receiver 90 , the hitch 100 cannot be easily removed from the vehicle without the special tool. This will provide the additional advantage of protection from theft.
Although not required for the present invention, in an exemplary embodiment the first and second wedge members 112 , 114 may be formed from a relatively soft material such as aluminum or a composite material, and the tubular insert 102 and ball mount 103 may be formed from a conventional rugged material such as steel.
As discussed above, the hitch 100 may alternatively be configured as a portion of any hitchable device, for example, a bicycle carrier, ski carrier, or the like. Also, although the current hitch 100 includes two generally cylindrical pistons 110 that engage the receiver 90 , it would be straightforward to change the number of pistons and/or to use other shapes or sizes of members for engaging the receiver. For example, it is contemplated that the second wedge member 114 may be provided with four smaller pistons or protrusions disposed generally at the corners of the second wedge member 114 , with corresponding apertures in the tubular sleeve member 102 .
Although a currently preferred embodiment has been described, many modifications may be made to this embodiment without departing from the present invention. For example, it is contemplated that the first and second wedge members 112 , 114 may be formed from some alternate material, such as a polymer or composite material. Also, where threadable connections are shown, it will be appreciated that other connection means, as are known in the art, may alternatively be used. It is also contemplated that a cover or other blocking means may be provided on the end of the tubular sleeve member 102 , to deter foreign matter from entering the member.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
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An anti-rattle hitch ( 100 ) includes a tubular insert ( 102 ) that is configured to be inserted into a receiver ( 90 ). A wedge mechanism comprising a first wedge member ( 112 ) and a second wedge member ( 114 ) are disposed in the insert, and have slidably engaged angled faces. The second wedge member includes one or more pistons that extend through piston ( 110 ) apertures in the insert such that the longitudinal position of the second wedge member is fixed. An adjustment member ( 120 ) adjusts the position of the first wedge member, thereby adjusting the piston position which can be biased against the receiver.
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FIELD OF THE INVENTION
This invention relates to oilfield pumping operations and more particularly to the pumping of dual fluid streams into a wellbore, one of the fluid streams comprising new or recycled fluids having a high Reid Vapor Pressure.
BACKGROUND OF THE INVENTION
In certain oilfield applications, pump assemblies are used to pump a treatment fluid from the surface down a wellbore, often at extremely high pressures. Such applications include but are not limited to hydraulic fracturing, cementing, acidizing, and pumping through coiled tubing, among other applications. In the example of hydraulic fracturing operations, a multi-pump assembly is often employed to direct a fracturing fluid into the wellbore and to a selected region(s) of the wellbore. The configuration of the well bore can vary and is subject to the type of completion most effective for the particular situation. The fracturing fluid is pumped from the wellbore into the formation to create “fractures” connecting the native reservoir to the wellbore that intersects the reservoir or the fracture network. To create such fractures, the fracturing fluid is pumped at pressures ranging from 1,000 to 15,000 psi or more. The mass flow rate of the fracturing fluid will vary depending upon what is required for the wellbore conditions. In addition, the fracturing fluid may or may not contain a propping agent, hereinafter called “proppant”. The proppant is used to keep the fracture “propped” open after the creation of the fracture as well as aiding in other fracturing mechanisms. These fractures provide communication pathways to the reservoir and allow formation deposits to flow into the wellbore and to the surface of the well. These additional pathways serve therefore to enhance the production of the well.
A power pump is typically employed for conveying the fracturing fluid into the wellbore during fracturing operations. A power pump is a positive displacement pump consisting of one or more cylinders each containing a piston or plunger. Such pumps are sometimes also referred to as positive displacement pumps, intermittent duty pumps, triplex pumps, or quintuplex pumps. This style of pump translates rotating motion to a linear actuation by means of a crankshaft—slider mechanism. The plunger is moved in two directions along a single axis. This motion moves the plunger in and out of a chamber in a pressure housing (typically referred to as a fluid end) in order to change the fluid volume of the chamber. Fluid enters the chamber through a one way valve as the plunger is sliding out of the chamber and the chamber volume increases. As the plunger slides into the chamber and decreases chamber volume, the fluid is displaced out of the chamber through a one way valve. This pumping action occurs in each of the fluid chambers of the fluid end and the summation of the individual compartments combines for a total output flow from the fluid end.
Multiple pumps are often employed simultaneously in large scale hydraulic fracturing operations. These pumps may be linked to one another through a common manifold, which mechanically collects and distributes the combined output of the individual pumps. For example, hydraulic fracturing operations often proceed in this manner with perhaps as many as twenty plunger pumps or more coupled together through a common manifold. A centralized computer system may be employed to direct the entire system for the duration of the operation.
However, the abrasive nature of fracturing fluids caused by the presence of proppant tends to wear out the internal components of the plunger pumps and associated piping components that are used to pump it. The repair, replacement and/or maintenance expenses for the internal components are extremely high, and the overall life expectancy is low for components used to convey fracturing fluids to the well bore.
To combat this state of affairs, pumping systems have been developed wherein a “dirty” stream of fracturing fluid (containing the abrasive proppant) and a “clean” stream of fracturing fluid (without proppant) is mixed in a common manifold at or in close proximity to the wellhead and delivered down hole to the zone to be fractured adjacent the wellbore. Each stream is supplied to the common wellhead manifold via a separate bank of positive displacement pumps. In such “split-stream” pumping systems, the excessive wear caused by entrained proppant is completely eliminated in the bank of pumps handling the “clean” fluids. Therefore, the extra maintenance is limited to the “dirty” bank of pumps.
An example of a split stream oilfield pumping system is disclosed in U.S. patent application Ser. No. 11/759,776 published under No. 2007/0277982 A1 on Dec. 6, 2007 to Shampine et al. Shampine however makes no provision for the use of recycled treatment fluid. Both of Shampine's fluid streams make use of new treatment fluid not previously recovered from the wellbore. Shampine moreover makes no provision for the use of fluids with a high Reid Vapor Pressure (RVP) that may or may not have been previously recovered from a wellbore.
Recycled treatment fluids demonstrate particular advantages for use in connection with fracturing operations. The recycling of fluid reduces the amount of new fluid required and the amount of fluid to be disposed of when the same fluid is used for a plurality of fracture treatments. Recycled treatment fluids present issues of their own however, which can limit their economic advantages. One of these issues is the Reid Vapor Pressure.
Under the ASTM Method D 323, Reid Vapor Pressure (“RVP”) is the absolute vapor pressure exerted by a liquid at 100° F. (37.8° C.). The higher this value, the more volatile the sample and the more readily it will evaporate. Unlike distillation data, RVP provides a single value that reflects the combined effect of the individual vapor pressure of the different petroleum fractions in a fluid sample in accordance with their mole ratios. It is thus possible for two wholly different products to exhibit the same vapor pressure at the same temperature—provided the cumulative pressures exerted by the fractions are the same. RVP plays a role in the prediction of hydrocarbon performance.
Recycled fracturing fluids typically have high RVP due to entrained hydrocarbons ingested when the fluids are pumped into and then recovered from oil and gas bearing formations. However, it is also contemplated that new (i.e. non-recycled) fluids may also have high RVP values. For this reason, the term “recycled” when used in reference to fluids will hereinafter refer generally to fracturing fluids having a high RVP value, regardless of whether the fluids are recycled or new. Some jurisdictions have regulations stipulating that such high RVP fluids for safety and environmental reasons are to be handled in a closed system to reduce or eliminate vaporization of the volatile hydrocarbon fluids, or the escape of the vapors to atmosphere. In the alternative, these high RVP fluids can undergo a re-conditioning process to remove the volatile hydrocarbon fractions as well as other substances. The need either to employ large scale containment systems or recondition the fracturing fluid prior to reuse, reduces the economic incentive to use them at all. Particularly, if a recycled fluid with a higher than acceptable RVP is to be blended with proppants, the size and expense of the containment system needed to enclose the proppant, the proppant auger and the blender is a significant disadvantage.
Accordingly, there is need for an oil field pumping system that can economically employ un-reconditioned recycled treatment fluids having high RVP without also requiring the use of large scale containment systems which would otherwise be necessary if the recycled fluid had to be blended with proppants.
SUMMARY OF THE INVENTION
It is thus an object of the present invention to provide an oilfield pumping system wherein recycled treatment fluids with a high RVP can be economically and safely reused in pumping operations.
Accordingly, in at least one embodiment, the present invention provides a system wherein at least two streams of fluid are pumped to a common mixing manifold in close proximity to or at the wellhead. The first stream is preferably comprised of a new fluid having a RVP lower than 14 kPa. This fluid can further contain wellbore treatment additives such as wellbore treatment chemicals and/or energizing fluid. This new fluid typically will meet fluid classifications suitable for either open or closed mixing systems. The base fluid for the new fluid can include but is not limited to hydrocarbons, acids, carbon dioxide, nitrogen or water or mixtures thereof.
The second stream comprises a recycled fluid that may or may not have a RVP lower than 14 kPa. This recycled fluid is typically a hydrocarbon fluid that may contain treatment chemicals and/or energizing fluid. In cases where the RVP of the recycled fluid is high (i.e. greater than 14 kPa), the recycled fluid is stored and delivered to the wellhead by a closed recycled fluid system.
The ratio of new fluid to recycled fluid in the mixture delivered to the wellhead will vary depending on the application.
Each fluid is stored in a separate containment device and is delivered to the wellhead by a separate pumping system, the choice of pumps for the systems depending on the particular application at hand. Pump types contemplated for use in connection with the present invention include but are not limited to progressive cavity, centrifugal or positive displacement pumps. Various pump arrangements are contemplated to deliver each stream to the common mixing manifold. These include but are not limited to multiple pumps connected in parallel or in series.
The benefits derived from the present invention will be readily apparent to those skilled in the art. Particularly, in at least one embodiment, the present invention can enable safe and economic recycling of high RVP fluids. The economic savings result from the fact that the recycled fluid does not require costly conditioning and less new fluids are required for the pumping operation. The present invention enables a continuous mixing of proppant and additives by integrating open and closed mixing systems. It is therefore unhindered by the constraints and added expense that would come with a closed system for mixing high RVP fluids and proppants.
Furthermore, in at least one embodiment, the present invention can maintain the high level of safety required in the petroleum production industry as the high RVP recycled fluid remains in a closed system, however the physical size of the closed system is reduced as only the recycled fluid streams need to be enclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a process diagram demonstrating an oilfield pumping system employing high RVP recycled production fluids.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be described for the purposes of illustration only in connection with certain embodiments; however, it is to be understood that other objects and advantages of the present invention will be made apparent by the following description of the drawings according to the present invention. While a preferred embodiment is disclosed, this is not intended to be limiting. Rather, the general principles set forth herein are considered to be merely illustrative of the scope of the present invention and it is to be further understood that numerous changes may be made without straying from the scope of the present invention.
FIG. 1 shows one embodiment of the present split stream oilfield pumping system 100 . In this example, the oilfield pumping system is preferably comprised of a recycled fluid subsystem 200 , a new fluid subsystem 300 , a wellhead 102 , and a common mixing manifold 104 . The present oilfield pumping system 100 could be designed to service a single wellhead or multiple wellheads located in the same general vicinity. Furthermore, it is contemplated that the oilfield pumping system 100 could be designed such that it is easily mobile and can be transported from wellhead to wellhead via tractor-trailer, truck, or in any other manner known to the skilled person in the art. It is also contemplated that the pumping system 100 could be integrated into one or more moveable trailers, tractor-trailer combinations, or truck mounts capable of being installed on a truck(s) or other vehicle.
Recycled treatment fluid is preferably recovered from the wellhead 102 , and stored in recycled fluid storage tanks 202 . However, the recycled fluid may be obtained from any number of sources and may be transported to the well site by any means, including by tanker truck. Entrained proppants and residual dirt and debris are removed from the recycled fluid by filtration, centrifuging, settling or any other method known in the art. Recycled fluid storage tanks 202 are supplied with recycled fluid from wellhead 102 by recovery pump 204 or other means. The pump can be any type of pump suited to the application. Storage tanks 202 are enclosed to provide a contained storage environment for the recycled fluid, which can possibly have a Reid Vapor Pressure (“RVP”) of higher than 14 kPa and in such instances is accordingly volatile.
Recycled fluid is pumped from storage tanks 202 by way of recycled fluid supply pump 206 , which typically is a centrifugal pump but can be any pump properly chosen by a person skilled in the art. Supply pump 206 provides recycled fluid to high pressure pumps 208 , which are typically positive displacement plunger pumps arranged in parallel between supply pump 206 and common mixing manifold 104 . However, other pump types and arrangements are contemplated. Because recycled fluid system 200 provides the “clean” stream to manifold 104 , it is the more compact of the two fluid subsystems which reduces the size of the containment field for high RVP fluids at substantial cost savings.
New fluid is stored in fluid storage tanks 302 or any other suitable receptacles know to those in the art. New fluid may be manufactured on site or transported to the worksite via typical tanker trucks. Storage tanks 302 can be enclosed or remain open to atmosphere, depending on the type of new fluid employed in the application, which would be chosen by the person skilled in the art. It is contemplated that new fluid could possibly be comprised of (but not limited to) hydrocarbons, acids, carbon dioxide, nitrogen and water.
New fluid is pumped from storage tanks 302 by way of new fluid supply pump 306 , which typically is a centrifugal pump but can be any pump properly chosen by a person skilled in the art. Supply pump 306 provides new fluid to blending subsystem 400 .
Blending subsystem 400 is preferably comprised of a delivery system 402 , such as an auger, to provide proppant from a bulk source to blender mixing chamber 404 . New fluid from supply pump 306 is blended with proppant from delivery system 402 at mixing chamber 404 , which produces a fracturing fluid with entrained proppant. It is contemplated that other wellbore additives chosen by the skilled person in the art could be added to the fracturing fluid at this time. Blending system 400 could further comprise a chemical additive injector to facilitate the addition of any additives. Assuming the new fluid has a RVP of less than 14 kPa, blending system 400 does not have to be closed.
The density of the fracturing fluid can be determined using a means 406 , such as a fluid density meter or a mass flow meter, located downstream from mixing chamber 404 , to determine the percentage of proppant entrained in the resultant fracturing fluid. Instrumentation measuring other characteristics of the resultant fracturing fluid is also contemplated at this point in the process. A bypass 408 located between the supply pump 306 and downstream of mixing chamber 404 allows new fluid to be directly pumped from new fluid subsystem 300 to a point downstream of the mixing chamber in situations where proppant is not required, such as when pumping a fluid pad to initiate a fracture in the treatment zone, or there is a need to isolate the mixing chamber.
Pumping system 100 preferably comprises a blending system discharge pump 410 to pump resultant fracturing fluid to high pressure pumps 308 , which are typically positive displacement plunger pumps arranged in parallel between discharge pump 410 and common mixing manifold 104 . However, other pump types and arrangements are contemplated.
As will be understood by a person skilled in the art, all pumps and piping components that are exposed to abrasive proppant entrained in the fracturing fluid are subject to accelerated wear. Accordingly, maintenance efforts and costs are reduced for the recycled fluid-side pumps, namely the centrifugal pumps and the positive displacement pumps which are not exposed. Furthermore, new fluid supply pump 306 also does not pump proppant-entrained fluid.
The resultant fracturing fluid from high pressure pumps 308 is mixed with the recycled fluid from high pressure pumps 208 in common mixing manifold 104 , typically located near the wellhead 102 . Blended fluid from the two streams is then delivered to wellhead 102 where it is directed down hole to the wellbore for use in fracturing operations. It is contemplated that common mixing manifold 104 and wellhead 102 can be integral with one another. Alternatively, the two fluid streams from pumps 208 and 308 can be mixed on the low pressure side downstream of mixing manifold 104 . The combined fluid streams can then be pumped into a single bank of plunger pumps.
It will be understood that the preferred embodiments mentioned here are merely illustrative of the present invention. Numerous variations in design and use of the present invention may be contemplated in view of the following claims without straying from the intended scope and field of the invention herein disclosed.
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A split stream oilfield pumping system is provided which utilizes recycled high Reid vapor pressure production fluids. The oilfield system is made up of two separate fluid streams: a first recycled fluid stream and a second new fluid stream. The recycled fluid stream is enclosed to reduce or eliminate vaporization of the recycled fluid, which typically will have a Reid vapor pressure >14 kPa. Wellbore treatment additives are added to the new fluid stream, and the resultant treatment fluid is mixed with the recycled fluid in a common manifold to provide a final wellbore treatment fluid to be delivered to the wellhead.
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This application claims priority from previously regularly filed U.S. Provisional Application filed on Oct. 17, 2000 under Application Ser. No. 60/240,847, by Harold Meredith having the title METAL CONSTRUCTION PANEL.
FIELD OF THE INVENTION
The invention relates to pre-engineered metal building systems and more specifically to an improved metal construction panel for use in forming the exterior wall of buildings.
BACKGROUND OF THE INVENTION
Currently in North America and Canada, the traditional method for building residential and some commercial buildings is wood framing, on top of a concrete foundation, after which the framing is either clad with brick or siding. With the disappearance of many of the best forests in North America, the lack of good lumber has driven up wood prices and therefore constructing homes using conventional wood framing technics is slowly becoming prohibitably too expensive.
A number of metal building systems are on the market including replacement of existing 2×4 and 2×6 wood studding and members with metal counter parts which are installed in a similar manner as the wood they are replacing. The disadvantage of this system is that the traditional framing and cladding process must occur, thereby there is little savings in regard to labour costs.
A number of other inventions have tried to address this problem by providing for a metal panel which provides both structural strength as well as exterior cladding for a building. Such building panels and methods of construction are described in U.S. Pat. No. 1,883,141 by Walters issued Oct. 18, 1932 titled Building Construction.
U.S. Pat. No. 2,023,814 titled: Metal Building Construction, issued on Dec. 10, 1935 to Samuel Lindsay and finally U.S. Pat. No. 3,568,388 titled Building Panel, filed by Charles T. Flachfbarth and Robert L. Parsons issued on Mar. 9, 1971. These patents describe building construction methods using a metal panel which serves both as a structural panel as well as an exterior architectural finished surface. By using these panels in one step, both framing and cladding of the house is completed. The advantage of the systems that they describe are the potentially reduced labour costs by eliminating one step in the building construction phase and in addition to that the improved strength of the house as well as the fire resistance and other safety features not found in wood constructed homes.
The disadvantage with these building systems is that they fail to address the problems of sealing off the joints in between the panels, thereby preventing water from seeping into the house due to capillary action. Secondly, the lack of flexibility in regard to choosing the exterior look. The user of such panels cannot choose alternate exterior cladding looks other than the one provided by the panels themselves.
SUMMARY OF THE INVENTION
The present invention an elongated metal construction panel for use in forming a portion of the vertical walls of a building structure by being fastened to an identical adjacent panel, the metal construction panel comprises:
(a) a front portion co-extensive with the length of the panel;
(b) end plates co-extensive with the length of the panel disposed substantially normal to said front portion and extending from distal ends of said front portion, said end plates defining the depth of said panel;
(c) flanges co-extensive with the length of the panel and extending inwardly from distal ends of said end plate, wherein said flanges are spaced from and parallel to said front portion; and
(d) wherein said end plates include end troughs co-extensive with the length of the panel such that when metal construction panels are placed adjacent each other by bringing into contact said end plates, said end troughs form a bonding channel adapted and sized for pouring bonding agents therein thereby securely fastening adjacent panels together and also waterproofing the joint between said end plates.
Preferably wherein said end troughs including a fluted section having a U shaped profile being co-extensive with the length of the panel.
Preferably wherein the width of said front portion is at least 3 times the depth of said end plate.
Preferably the width of said front portion is preferably 4 times the depth of said end plate.
Preferably wherein the depth of said end plate being at least 3½ inches.
Preferably wherein the front portion includes female dovetail grooves co-extensive with the length of the panel and adapted to co-operate with an attachment clip for fastening articles to said attachment clip.
Preferably wherein said dovetail grooves define fluted surfaces disposed at an angle theta less than 90°.
Preferably wherein said angle theta is preferably 87°.
Preferably wherein said attachment clip defines male dovetail tabs cooperating with said female dovetail grooves to hold said clip within said dovetail grooves, whereby said tabs are joined together in spaced apart relationship by a joining member.
Preferably wherein said tabs are resiliently biased such that said tabs are compressed for placing said tabs within said female dovetail grooves and upon release said resiliently biased tabs hold said attachment clip within said female dovetail grooves.
Preferably wherein said attachment clip further comprises wings extending from said tabs and oriented substantially parallel and adjacent to said front portion for securely fastening said clip to said panel.
Preferably wherein said attachment clip further comprises an attachment lip rigidly connected to said joining member for fastening articles thereto.
Preferably wherein said attachment lip is adapted for fastening vinyl siding thereto.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only, with references to the followings drawings in which:
FIG. 1 is a schematic top perspective view of the metal construction panel.
FIG. 2 is a partial cut away schematic showing the installation and joining of two metal construction panels together with drywall.
FIG. 3 is a top cross sectional view of two metal construction panels joined together showing a clip attached to one panel.
FIG. 4 is a schematic perspective assembly view of metal construction panels upon a foundation illustrating how the metal construction panels would be joined together.
FIG. 5 is a front perspective view of an attachment clip for use with the metal construction panel.
FIG. 6 is a view of the metal plank which would be bent and folded to produce the attachment clip and also showing how the attachment clip cooperates with the metal construction panel.
FIG. 7 is a top plan view of the attachment clip.
FIG. 8 is a cross-sectional schematic view of two metal construction panels joined together showing how a strengthening member can be used at such a junction.
FIG. 9 is a schematic cross-section view of metal construction panels joined together at a comer showing the use and the insertion of a strengthening member at the comer section as well as an attachment flange for fastening wall boards onto the interior comer portion.
FIG. 10 is a schematic cross-section view of an alternate comer arrangement showing two metal construction panels intersecting at a comer post.
FIG. 11 is a schematic prospective view showing a tool installing an attachment clip into a dove tail groove of a metal construction panel.
FIG. 12 is a top cross sectional view of two metal construction panels of the presently preferred type showing the modified flange arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first of all to FIG. 1 which schematically shows a metal construction panel showing generally as 20 having a front 22 , end plates 24 , flanges 26 , end troughs 28 , and dovetail grooves 30 . Front 22 of panel 20 has length 102 , width 104 and end plates 24 have depth 106 . The panel is oriented vertically along longitudinal axis 90 . Front 22 has front first end 92 and front second end 94 . End plates 24 include end plate distal end 96 .
Referring now to FIG. 2 which schematically illustrates the joining of two end plates 24 of metal construction panels 20 . Metal construction panels 20 are joined together when end plates 24 come in contact with each other, such that end troughs 28 form a bonding channel 32 which is a rectangular tubular section running longitudinally along the length of metal construction panel 20 . The tubular section can take on any number of shapes other than shown here. Metal construction panels 20 can be mechanically fastened together using fastener attachments 32 which could for example be a nut and bolt arrangement mechanically connecting end plates 24 together. Preferably, however in order to seal off the joint formed by joining end plates 24 together, a bonding material is poured into bonding channel 32 thereby sealing off the groove or joint formed between end plates 24 therefore preventing water from entering from front 22 of metal construction panels 20 via capillary action and into the interior of the home.
From FIG. 2, one can see that front 22 forms the exterior architectural portion of the home, whereas flanges 26 serve as fastening attachments for screwing or nailing wallboard 40 onto flanges 26 . Wallboard 40 can be the conventional drywall sheets which are used in conventional home construction now and/or can be another type of interior surfacing which is suitable. Panel 20 preferably is fabricated from sheet steel or aluminum and is preferably fabricated using the roll forming process.
Referring now to FIG. 3 showing in cross section two metal construction panels 20 joined together, and in particular dovetail grooves 30 are shown having an angle theta 42 of approximately 87 degrees. Further attachment clip 38 is shown in situ in dovetail groove 30 indicating how attachment clip 38 is mounted to a metal construction panel 20 . In this view, also one can see how bonding channel 32 is formed by adjacent end troughs 28 when end plates 24 are brought together.
Referring now to FIG. 4, a number of metal construction panels 20 are shown in schematic fashion mounted together onto a foundation 52 . Typically on top of a concrete foundation 52 , a foundation channel 50 would be mounted into place and there upon metal construction panels 20 would be fastened such that they extend vertically upward from foundation 52 , along longitudinal axis 90 . Those skilled in the art will see that metal construction panel 20 serves not only as a structural wall member but also as an exterior architectural panel for the building construction. Metal construction panels 20 are joined at end plates 24 either adhesively by pouring adhesive into bonding channel 32 and/or including mechanical fastening attachments 34 shown in FIG. 2 . It is apparent that front 22 of metal construction panels 20 is disposed outwardly creating the exterior cladding of the building. In addition, dovetail grooves 30 extend vertically along metal construction panels 20 for accommodating attachment clips 38 as will be explained here below. Typically once metal construction panels 20 have been erected onto foundation channel 50 , a top plate 54 is mounted and fastened to the top portion of metal construction panels 20 which can be used for subsequent erection of the roof truss sections or other roof construction.
Attachment Clip
Referring now to FIGS. 5, 6 and 7 which schematically shows the details of attachment clip 38 shown in situ in FIG. 3, attachment clip 38 includes joining member 61 , right tab 60 , left tab 62 , right wing 68 , left wing 70 , apertures 66 , and attachment lip 64 . In practice, attachment clip 3 8 would be made from a sheet of steel and the metal blank prior to bending is shown as clip blank 74 in FIG. 6 . The dashed lines in FIG. 6 represent the bend lines in order to fabricate attachment clip 38 into the finished product as shown in FIG. 5 . In other words clip bank 74 is bent along the dashed lines to produce attachment clip 38 . Attachment clip 38 is so designed such that right tab 60 and left tab 62 can be resiliently flexed to fit and cooperate with dovetail grooves 30 of metal construction panels 20 .
In use dovetail grooves 30 and metal construction panels 20 have an angle theta 42 of approximately 87 degrees, whereas right tab 60 makes an angle alpha 72 of approximately 85 degrees. Attachment clip 38 is installed into dovetail groove 30 by deflecting or compressing right tab 60 and left tab 62 such that they fit into dovetail grooves 30 of metal construction panel 20 . Attachment clip 38 as shown in FIG. 3 is held in dovetail groove 30 by the biasing force imparted by right tab 60 and left tab 62 onto the inner surfaces of the dovetail grooves 30 of metal construction panel 20 . In addition, apertures 66 can be used to instal fastening screws for rigidly attaching and screwing attachment clip 38 to the metal construction panel 20 .
Attachment lip 64 extends outwardly from front 22 of metal construction panel 20 and is used for attaching various cladding materials should the user of metal construction panel 20 wish to have an alternative exterior look than the one provided by front 22 of metal construction panel. In this manner by placing numerous attachment clips 38 onto dovetail grooves 30 , one can clad the entire exterior surface or the front 22 of metal construction panel 20 and provide for any particular look or architectural appearance the end user desires. For example, brick face, siding, vinyl siding, wood siding, panelling, stucco or any other currently known architectural type finishes can be applied to the front 22 of metal construction panels 20 .
Those skilled in the art will appreciate the advantages of the current system namely, one could potentially avoid having to have separate framing and architectural finishing surfaces applied to the exterior of the home, but yet retain the flexibility of adding a particularly architectural surface to the exterior of the home, depending on the end use requirement. Furthermore, using metal construction panels 20 , a totally waterproof construction is used due to filling bonding channels 32 with a bonding agent, thereby preventing capillary action of water penetrating through the connection seam between adjacent metal construction panels 20 .
The bonding agents can be commercially available exterior caulking compounds including silicone, epoxy or polyester based compounds.
Referring now to FIG. 11, which in schematic fashion shows the installation of an attachment clip 38 being installed into a dove tail groove 30 . Installation tool 190 as shown in FIG. 11 having tips 192 which are received in apertures 66 of left and right wing 70 and 68 of attachment clip 38 . Installation tool 190 is a hand held tool in which handles 198 are compressed in a direction as shown by arrows 194 thereby urging together right and left tab 60 and 62 of attachment clip 38 . Right and left tabs of attachment clip 38 are resiliently bias such that by compressing right and left tab 60 and 62 , the attachment clip 38 can be urged into dove tail grooves 30 such that right and left wing 68 and 70 lie substantially parallel and adjacent to the back portion of dove tail grooves 30 . By removing tips 192 of installation tool 190 from attachment clip 38 , leaves attachment clip 138 in position in dove tail groove 30 . By reversing the procedure described above the attachment clip 38 can be removed from dove tail groove 30 . Note that apertures 66 therefore have two functions, first of all for installing and uninstalling attachment clip 38 from dove tail groove 30 by cooperating with tips 192 of an installation tool 190 and secondly for mechanically fastening attachment clip 38 to metal construction panel 20 by placing screws through apertures 66 into the back of dove tail groove 30 thereby permanently affixing attachment clip 38 to metal construction panel 20 .
Strengthening Member
Referring now to FIGS. 8 and 9, showing metal construction panels 20 attached together and a strengthening member 110 used to provide additional compressive strength as well as stiffening to the structure for providing enough structural strength for the building to support the roof and other structural weight and also to provide wind and earthquake resistance by the addition of strengthening member 110 .
Looking to FIG. 8 which shows in cross-section the profile of strengthening member 110 ; strengthening member 110 has an end trough section 128 , end plate portions 124 and end flange sections 127 and is designed to nest inside and conform with the contour of end plate 24 of metal construction panel 20 . Referring now to FIG. 9, strengthening member 110 is shown in situ at a comer section of a metal construction panel 20 and is nested and adjacent to the end plate 24 of construction panel 20 . In addition to this the metal construction panel 20 along with the strengthening members 110 are fastened with anchors 112 into concrete at the base and with mechanical fasteners as shown into the metal construction panel 20 .
FIG. 9 in particular shows a comer construction possibility by using two metal construction panels 20 to form said comer. The reader will note that no custom section or special section is required in order to form a comer. In order to attach wall board 40 onto the flanges 26 of metal construction panel 20 in a comer as depicted, an attachment flange 130 is required in order to fasten the wall boards 40 together.
Strengthening members 110 are co-extensive with the entire length of metal construction panel 20 and can be placed periodically along the walls formed by metal construction panels 20 . For example if extra strength is required, strengthening members 110 can be placed at every end plate 24 of metal construction panel 20 found in a wall. Strengthening members 110 are especially used where the gauge or thickness of the material used to form metal construction panel 20 is too thin to support the structural weight of the building and/or to provide enough stiffness or enough wind resistance. By the use of strengthening members 110 , one can form metal construction panel 20 out of a thinner gauge material and yet obtain enough structural strength and stiffness by including additional strengthening members 110 as required. This reduces the overall costs of manufacturing metal constructions panels and allows one to produce the lightest possible weight panel for a given application.
Referring now to FIG. 10 which shows a heavy duty comer construction using a comer post 150 which is a tubular metal comer post construction. As shown in the previous Figures, anchors 112 are used to connect metal construction panel 20 to comer post 150 .
Presently Preferred Metal Construction Panel
FIG. 12 shows a presently preferred embodiment of metal construction panel 220 . In most respects metal construction panel 220 is analogous to metal construction panel 20 in that the front face 222 includes dove tail grooves 30 and also includes end plates 24 having end trough 28 forming a bonding channel 32 between two metal construction panels 220 forming a joint 31 . These items remain unchanged and identical to the previously described metal construction panel 20 as shown in FIG. 1 . The modification to metal construction panel 220 is the modified flange 226 which includes dimples 227 as shown in FIG. 12 . The function of Flange 226 is for mounting wall board and/or other interior finishing materials onto flange 226 as shown in FIG. 12 . Wall board 40 as shown in FIG. 12 can either be nailed and/or screwed into any portion of flange 226 in order securely fasten wall board 40 onto flange 226 . By providing dimples 227 , the wall board 40 makes contact with flange 226 at contact points 229 as shown in FIG. 12 . This configuration provides for additional structural strength by increasing the stiffness of metal construction panel 220 by introducing dimples 227 which run along the entire length 102 of metal construction panel 220 and also provide additional compressive strength due to the increased stiffness and cross sectional area of the load bearing member.
The other advantage provided by dimples 227 on flanges 226 is the reduced heat conduction from the front face 222 of metal construction panel through end plate 24 and out through flanges 226 and into the interior of the building through wall board 40 . The amount of heat that can be conducted through metal construction panel 220 and into wall board 40 is significantly reduced due to the reduction in the amount of contact surface of flange 226 with wall board 40 . Contact between wall board 40 and 226 is limited to contact points 229 as shown in FIG. 12 . Dimples 227 can be of different geometries than shown in FIG. 12 . As shown in FIG. 12, dimple 227 are crescent shaped or half moons or half circles in shape, however, they also may be squared off, triangular, V-shaped, and/or any other shape which minimizes the contact between wall board 40 and flange 226 .
It should be apparent to persons skilled in the arts that various modifications and adaptation of this structure described above are possible without departure from the spirit of the invention the scope of which defined in the appended claim.
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The present invention an elongated metal construction panel for use in forming a portion of the vertical walls of a building structure by being fastened to an identical adjacent panel, the metal construction panel comprising a front portion co-extensive with the length of the panel; end plates co-extensive with the length of the panel disposed substantially normal to said front portion and extending from distal ends of said front portion, said end plates defining the depth of said panel; flanges co-extensive with the length of the panel and extending inwardly from distal ends of said end plate, wherein said flanges are spaced from and parallel to said front portion; and wherein said end plates include end troughs co-extensive with the length of the panel such that when metal construction panels are placed adjacent each other by bringing into contact said end plates, said end troughs form a bonding channel adapted and sized for pouring bonding agents therein thereby securely fastening adjacent panels together and also waterproofing the joint between said end plates.
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The government has rights in this invention pursuant to Contract Number DE-AC02-80ET26225 awarded by the U.S. Department of Energy.
This invention to relates to recovery of hydrogen iodide from aqueous solutions and more particularly to the recovery of hydrogen iodide from a solution of hydrogen iodide, water and iodine.
BACKGROUND OF THE INVENTION
A process for producing hydrogen from water has been developed using the sulfur-iodine cycle, sometimes termed a water-splitting process, which utilizes the Bunsen reaction. The process is disclosed in detail in U.S. Pat. No. 4,089,940, which issued on May 16, 1978 to John H. Norman et al., and reacts water, SO 2 and I 2 under conditions which create two liquid phases--an aqueous phase containing the H 2 SO 4 product and a relatively dry phase containing the major portion of the HI product plus iodine and some water. There has been some difficulty in obtaining a relatively dry HI product because HI and H 2 O form an azeotrope. Phosophoric acid has been used to break this azeotrope, as set forth in U.S. Pat. No. 4,127,644, issued Nov. 28, 1978 to John H. Norman et al. Extractive distillation is a somewhat energy-intensive processing step, and the reconcentration of the phosphoric acid is a particularly energy-intensive step.
A further improvement was made with respect to recovery of hydrogen iodide which utilized the high-pressure creation of two separate liquid phases when compositions within certain precentage ranges of HI, I 2 and H 2 O were present, which process is described in detail in co-pending U.S. application Ser. No. 073,566, filed Sept. 7, 1979 in the names of Dennis R. O'Keefe et al. However, effective use of such process generally requires some H 3 PO 4 treatment or the like in order to increase the HI percentages within the composition, again requiring the relatively energy-intensive recovery of the phosphoric acid. Accordingly, the search continued for still less energy-intensive methods for recovering hydrogen iodide.
SUMMARY OF THE INVENTION
A method has been devised for using HBr to create a solvent extraction process via the formation of two liquid phases. A dry phase contains HBr, I 2 (if present) and HI, and a wet phase contains HBr and H 2 O. After separation of the two phases, HI is obtained in a utilizable form from the dry phase, or HI can be thermally decomposed in the presence of HBr following separation of I 2 therefrom. A portion of the HBr is recovered and recycled using a high-pressure azeotrope-shifting step, and another portion may be recycled along with H 2 O to the Bunsen reaction--assumming it is being used to create the initial solution being treated.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a schematic illustration of a system for carrying out an overall water-splitting process with the portion encompassed within the broken lines generally showing the present improvement, recognizing that HI liquid decomposition was earlier known.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
It has been found that HBr extraction of HI from an aqueous solution of HI (which may also include I 2 ) is feasible because the relative distribution coefficient is quite high with respect to HI, i.e., about 5. The relative distribution coefficient is defined in terms of the mole fractions of the hydrogen halides in the two liquid phases as follows: ##EQU1## Therefore, the addition of sufficient HBr to create such a two-phase liquid system makes countercurrent extraction of the HI from the solution feasible. In fact, it has been found that about one mole of HI in the product solution from the Bunsen reaction can be extracted by about 2.4 moles of HBr and that substantially all of the HI present can be extracted in a multistage countercurrent extractor.
Following extraction, the dry HI--HBr phase permits relatively straightforward distillation of HBr therefrom at a bottoms temperature in the range of about 300° C. to 400° C. at about 40 atmospheres. Alternatively, it is possible to directly decompose the HI as a part of a liquid decomposition process in the presence of the HBr. The catalytic decomposition of liquid hydrogen iodide is disclosed in detail in U.S. Pat. No. 4,258,026, which issued on Mar. 24, 1981 to Dennis R. O'Keefe et al., the disclosure of which is incorporated herein by reference.
The invention is illustrated in the FIGURE as part of an overall water-splitting process for creating hydrogen and oxygen from water, which is based upon the Bunsen reaction. Details of the individual steps are set forth in the aforementioned U.S. Patents and accordingly are not repeated hereinafter, except that broad reference is made to the steps sufficient to understand the application of the present invention thereto. It should be understood that the invention is also applicable to recovering HI from an aqueous solution thereof which is substantially iodine-free.
Briefly, a main reactor 11 is provided wherein the chemical reaction of H 2 O, I 2 and SO 2 is carried out to form H 2 SO 4 and HI in accordance with the Bunsen reaction under conditions such that two liquid phases are created. The heavier of the two phases, sometimes referred to hereinafter as the first phase, is the hydrogen iodide-bearing phase, whereas the second phase is the lighter or less dense of the two phases and is the H 2 SO 4 -bearing phase. In the FIGURE, the lighter phase is referred to as phase A and the heavier phase as phase B. The two-phase mixture exits from the main reactor and enters a phase separator 13 wherein the separation of the two phases occurs.
The heavier phase B is preferably passed first to a stripper 15 where excess sulfur dioxide is removed by subjection to a vacuum or inert gas stripping. Mild heating may be used to increase its vapor pressure. The sulfur dioxide is returned to the main reactor 11, and the resultant, degassed stream is conducted to an HBr extractor 17.
The extractor 17 is preferably operated as a countercurrent extractor with the degassed phase B entering the top and the HBr being supplied at one or more lower locations. As soon as the capacity of the phase B to dissolve HBr is satisfied, two distinct liquid phases are created, which are hereinafter termed a wet phase and a dry phase and which change in composition as they transit the multistage column as extraction proceeds. The operation of the extractor 17 is such that at least a major portion of the HI in the incoming phase B is extracted into the HBr dry phase, and accordingly at least a major portion of the H 2 O remains in the wet phase.
The wet phase, depending on temperature, is the more dense of the two and upon exiting consists essentially of H 2 O and HBr; it preferably contains substantially all of the original water and about 2 moles of HBr for every mole of HI that was initially present in phase B not accounting for initially present HBr. Sufficient HBr is preferably added in the extraction to remove substantially all of the HI from the aqueous incoming phase B so that the less dense dry phase, when it exits the top of the extractor, contains HBr, substantially all of the HI, I 2 and less than about 1 weight % H 2 O. The creation of these wet and dry phases is relatively temperature-insensitive, and it is considered feasible to operate the HBr extractor at a suitable temperature as low as about 0° C. and up to a temperature of about 90° C. for the HBr inlet stream and about 130° C. for the heavy phase B inlet stream. Because of this relative temperature insensitivity, it may be preferred to operate the HBr extractor 17 at a temperature which is determined by the remainder of the system, namely the temperature of the main reactor or of the SO 2 stripper 15, and in this respect operation may be at about 100° C. However, it may also be preferred to have nearly all of the I 2 exit in the dry phase, and this end may be achieved in some instances by operating at a slightly higher temperature, e.g. 115° to 120° C.
The dry phase exiting from the top of the extractor 17 may contain, for example, about 70 mole % HI and about 30 mole % HBr, calculated on an H 2 O- and I 2 -free basis and is routed to an HBr separator 19 where a three-way separation is effected. The separator is operated essentially in two steps to first remove the iodine by boiling off the HBr and HI, and then the HBr and HI are separated by a condensation step. The separator is operated to boil off HI and HBr at a bottoms temperature of between about 300° C. and 400° C. and an appropriate pressure, e.g. about 40 atmospheres. The HBr is returned to the extractor 17, and the HI is routed to a liquid HI decomposition reactor 21.
The decomposition of the liquid HI is carried out in accordance with the teaching of aforementioned U.S. Pat. No. 4,258,026, operating at temperatures up to about 150° C. and using a suitable platinum group metal catalyst. The stream exiting from the decomposition reactor 21 contains product H 2 and I 2 and undecomposed HI and is routed to a still 23. Alternatively, it is considered feasible to operate the separator 19 so as to only remove the I 2 and not effect a separation of HBr and HI, allowing both of these hydrogen halides to flow to the liquid HI decomposer. The liquid HI decomposition reaction can take place in the presence of substantial amounts of HBr without severely affecting either the catalyst or the reaction rate, and accordingly, it is considered feasible to treat the dry HI-HBr phase to carry out the decomposition before recovering the HBr and returning it to the HBr extractor 17. Moreover, it may not be absolutely necessary to separate the I 2 before decomposing the HI; however, the presence of I 2 would tend to lower the driving force of the decomposition reaction.
In the process shown in the FIGURE, the still 23 is operated at a bottoms temperature of about 440° C. and a pressure of about 50 atm. Gaseous H 2 , with an equilibrium partial pressure of HI, comes off the top of the still, whereas liquid HI is recovered from an intermediate location and the iodine is recovered from the bottom. The HI is returned to the liquid HI decomposition reactor 21.
The gaseous hydrogen stream is routed to a scrubber 25 where a minimal amount of water is used to remove the residual HI to produce a clean hydrogen product stream 27. The scrubbing liquid with the HI is returned to the main reactor 11.
The wet phase exits from the bottom of the countercurrent extractor 17 is routed to an HBr still 29. The HBr--H 2 O solution from the countercurrent extractor 17 is highly superazeotropic in HBr, and much of the HBr can be distilled from this mixture without a large energy expenditure. For example, the HBr still 29 may be operated at a bottoms temperature of about 125° C. and atmospheric pressure. At these conditions, the azeotrope is about 17 mole percent HBr and 83 mole percent H 2 O, which is to be compared with an incoming wet phase containing about 40 mole percent HBr. The HBr leaving the still 29 is condensed and returned to the HBr extractor 17.
It has been found that the HBr--H 2 O azeotrope, which is about 17 mole percent HBr at one atmosphere, changes to only about 7 mole percent HBr when the pressure is increased to about 200 atmospheres. Accordingly, the azeotrope from the low-pressure still 29 is routed to a high-pressure still 31 which is operated at about 200 atmospheres and a temperature of about 395° C. Accordingly, additional HBr is distilled from the solution, and it is also condensed and returned to the HBr extractor 17. It has further been found that the remaining azeotrope, which is about 7 mole percent HBr and 83 mole percent H 2 O, can be returned to the main reactor 11 and utilized directly therein because the presence of the HBr is only slightly detrimental to the basic Bunsen reaction which is occurring therein. Utilization of the azeotrope in this manner is extremely advantageous inasmuch as a further highly energy-intensive extractive distillation of water is avoided. Generally, it is felt that the high-pressure still 31 should be operated at a pressure between about 150 and about 225 atmospheres and a corresponding temperature in order to take good advantage of the shifting of the azeotrope to not more than about 8 mole % HBr. The returned HBr from the azeotrope is distributed in both liquid phases created in the main reactor 11. The HBr content of the heavier phase B simply adds to the total amount of HBr in the extractor 17.
The aqueous phase A from the phase separator 13 is routed first to an H 2 SO 4 boost reactor 35 where it is mixed with the iodine streams recovered from the HBr separator 19 and the product still 23 and with additional recovered SO 2 , while it is maintained at essentially the same temperature and pressure as the main reactor 11. As a result, the Bunsen reaction proceeds further to the right producing additional H 2 SO 4 . The H 2 SO 4 concentration, for example, can be boosted or increased from a concentration of about 50 percent to about 57 percent by creating additional H 2 SO 4 from the H 2 O present in the aqueous phase A. The concept of the boost reactor is to provide sufficient liquid iodine to constitute a separate liquid iodine phase which will be in equilibrium with the aqueous phase A and to saturate the liquid in the reactor 35 with SO 2 . The liquid I 2 phase contributes I 2 to the reaction and also extracts the HI produced by the reaction from the aqueous phase. In addition, it extracts a significant amount of water which is also advantageous in requiring less water to be removed in a subsequent step. The output from the boost reactor 35 is a gaseous stream containing primarily O 2 and SO 2 with other vapors present at their equilibrium partial pressures, the liquid I 2 phase and the aqueous phase. The liquid I 2 phase, which carries substantially all of the HI, some water and some HBr, is routed along with the gaseous stream back to the main reactor 11. The aqueous phase is directed to an HBr still 37.
The HBr still 37 is operated at a bottoms temperature of about 170° C. and a pressure of about 2 atm. to distill an overhead stream of HBr and SO 2 . Sufficient concentrated H 2 SO 4 is added to the still 37 from a later step to break the H 2 O--HBr azeotrope. The HBr may be condensed from the stream in the absence of H 2 O and returned to the HBr extractor 17. The separated SO 2 is bubbled into the liquid in the boost reactor 35 and helps provide the desired SO 2 saturation therein. The bottoms from the HBr still consist essentially of water and H 2 SO 4 and proceed to a concentrator 39.
The concentrator 39 may be operated at a temperature of about 360° C. and a pressure of about 2 atm. to evaporate the water and separate a bottom stream of fairly dry H 2 SO 4 . The water is condensed and routed to an oxygen scrubber 41 which is employed to remove residual vapors, i.e., SO 2 and others, in the gaseous stream exiting overhead from the main reactor 11 to create a substantially pure oxygen stream. The origin of the oxygen is described hereinafter.
The dry H 2 SO 4 is routed to a boiler 43 where it is vaporized at a temperature of at least about 335° C. (1 atm.), resulting in some breakdown to H 2 O and SO 3 . The vapor stream from the boiler 43 is directed to an H 2 SO 4 catalytic decomposer 45. The decomposition reaction may be carried out in accordance with the teaching of U.S. Pat. No. 4,314,982, issued Feb. 9, 1982 to John H. Norman et al. The vapor stream exiting from the decomposer 45 is immediately delivered to a condenser 47. The gaseous SO 2 and O 2 stream from the condenser 47 is returned to the boost reactor 35 where the SO 2 contributes to the desired SO 2 saturation therewithin. The oxygen eventually finds its way to the main reactor and then to the scrubber 41. The condensate stream from the condenser 47 is recycled to the concentrator 39.
The present invention is considered to provide a substantial improvement over earlier methods of providing dry hydrogen iodide utilizing extractive distillation with H 3 PO 4 or the like, because such operations were energy-intensive from the standpoint that all of the water had to eventually be distilled from the H 3 PO 4 . In accordance with the present invention, the HBr treatment allows the creation of a dry HI composition from an aqueous solution of HI (which may contain other components such as I 2 ) wherein the necessity for boiling water is very substantially reduced in favor of the less energy-intensive evaporation of HBr, which is a gas at ambient conditions.
Although the invention has been described with respect to certain preferred embodiments, it should be understood that changes and modifications as would be obvious to one having the ordinary skill in the art may be made without departing from the scope of the invention which is defined by the claims appended hereto. For example, the H 2 SO 4 boost reactor 35 may be operated as a countercurrent extractor with the I 2 stream flowing countercurrent to phase A under conditions so that substantially all of the HBr is extracted into the iodine phase and thus returned to the main reactor 11; and in such an instance, it would be possible to eliminate the HBr still 37 and allow any residual HBr in the aqueous phase to be returned to the main reactor with the water from the H 2 SO 4 concentrator 39 via the O 2 scrubber 41.
Particular features of the invention are emphasized in the claims which follow.
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A method of extraction of HI from an aqueous solution of HI and I 2 . HBr is added to create a two-phase liquid mixture wherein a dry phase consists essentially of HBr, I and HI and is in equilibrium with a wet phase having a far greater HBr:HI ratio. Using a countercurrent extractor, two solutions can be obtained: a dry HBr--HI--I 2 solution and a wet essentially HBr solution. The dry and wet phases are easily separable, and HI is recovered from the dry phase, after first separating I 2 , as by distillation. Alternatively, the HI-HBr liquid mixture is treated to catalytically decompose the HI. HBr is recovered from the wet phase by suitable treatment, including high-pressure distillation, to produce an H 2 O--HBr azeotrope that is not more than 25 mole percent HBr. The azeotrope may be returned for use in an earlier step in the overall process which results in the production of the aqueous solution of HI and I 2 without major detriment because of the presence of HBr.
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RELATED APPLICATION
This is a continuation-in-part patent application of U.S. Pat. application Ser. No. 08/414,558, filed on Mar. 31, 1995, and entitled "Method and Apparatus for Testing Wells" now abandoned.
FIELD OF INVENTION
This invention relates to the testing of underground formations or reservoirs. More particularly, this invention relates to a method and apparatus for isolating a downhole reservoir, and testing the reservoir fluid.
BACKGROUND OF THE INVENTION
While drilling a well for commercial development of hydrocarbon reserves, numerous subterranean reservoirs and formations will be encountered. In order to discover information about the formations, such as whether the reservoirs contain hydrocarbons, logging devices have been incorporated into drill strings to evaluate several characteristics of the these reservoirs. Measurement while drilling systems (hereinafter MWD) have been developed which contain resistivity and nuclear logging devices which can constantly monitor some of these characteristics while drilling is being performed. The MWD systems can generate data which includes hydrocarbon presence, saturation levels, and porosity data. Moreover, telemetry systems have been developed for use with the MWD systems, to transmit the data to the surface. A common telemetry method is the mud-pulsed system, an example of which is found in U. S. Pat. No. 4,733,233. An advantage of an MWD system is the real time analysis of the subterranean reservoirs for further commercial exploitation.
Commercial development of hydrocarbon fields requires significant amounts of capital. Before field development begins, operators desire to have as much data as possible in order to evaluate the reservoir for commercial viability. Despite the advances in data acquisition during drilling, using the MWD systems, it is often necessary to conduct further testing of the hydrocarbon reservoirs in order to obtain additional data. Therefore, after the well has been drilled, the hydrocarbon zones are often tested by means of other test equipment.
One type of post-drilling test involves producing fluid from the reservoir, collecting samples, shutting-in the well and allowing the pressure to build-up to a static level. This sequence may be repeated several times at several different reservoirs within a given well bore. This type of test is known as a Pressure Build-up Test. One of the important aspects of the data collected during such a test is the pressure build-up information gathered after drawing the pressure down. From this data, information can be derived as to permeability, and size of the reservoir. Further, actual samples of the reservoir fluid must be obtained, and these samples must be tested to gather Pressure-Volume-Temperature data relevant to the reservoir's hydrocarbon distribution.
In order to perform these important tests, it is currently necessary to retrieve the drill string from the well bore. Thereafter, a different tool, designed for the testing, is run into the well bore. A wireline is often used to lower the test tool into the well bore. The test tool sometimes utilizes packers for isolating the reservoir. Numerous communication devices have been designed which provide for manipulation of the test assembly, or alternatively, provide for data transmission from the test assembly. Some of those designs include signaling from the surface of the Earth with pressure pulses, through the fluid in the well bore, to or from a down hole microprocessor located within, or associated with the test assembly. Alternatively, a wire line can be lowered from the surface, into a landing receptacle located within a test assembly, establishing electrical signal communication between the surface and the test assembly. Regardless of the type of test equipment currently used, and regardless of the type of communication system used, the amount of time and money required for retrieving the drill string and running a second test rig into the hole is significant. Further, if the hole is highly deviated, a wire line can not be used to perform the testing, because the test tool may not enter the hole deep enough to reach the desired formation.
There is also another type of problem, related to down hole pressure conditions, which can occur during drilling. The density of the drilling fluid is calculated to achieve maximum drilling efficiency while maintaining safety, and the density is dependent upon the desired relationship between the weight of the drilling mud column and the downhole pressures which will be encountered. As different formations are penetrated during drilling, the downhole pressures can change significantly. With currently available equipment, there is no way to accurately sense the formation pressure as the drill bit penetrates the formation. The formation pressure could be lower than expected, allowing the lowering of mud density, or the formation pressure could be higher than expected, possibly even resulting in a pressure kick. Consequently, since this information is not easily available to the operator, the drilling mud may be maintained at too high or too low a density for maximum efficiency and maximum safety.
Therefore, there is a need for a method and apparatus that will allow for the pressure testing and fluid sampling of potential hydrocarbon reservoirs as soon as the bore hole has been drilled into the reservoir, without removal of the drill string. Further, there is a need for a method and apparatus that will allow for adjusting drilling fluid density in response to changes in downhole pressures, to achieve maximum drilling efficiency. Finally, there is a need for a method and apparatus that will allow for blow out prevention downhole, to promote drilling safety.
SUMMARY OF THE INVENTION
A formation testing method and a test apparatus are disclosed. The test apparatus is mounted on a work string for use in a well bore filled with fluid. The work string can be a conventional threaded tubular drill string, or coiled tubing. It can be a work string designed for drilling, re-entry work, or workover applications. As required for many of these applications, the work string must be one capable of going into highly deviated holes, or even horizontally. Therefore, in order to be fully useful to accomplish the purposes of the present invention, the work string must be one that is capable of being forced into the hole, rather than being dropped like a wireline. The work string can contain a Measurement While Drilling system and a drill bit, or other operative elements. The formation test apparatus includes at least one expandable packer or other extendable structure that can expand or extend to contact the wall of the well bore; means for moving fluid, such as a pump, for taking in formation fluid; and at least one sensor for measuring a characteristic of the fluid. The test apparatus will also contain control means, for controlling the various valves or pumps which are used to control fluid flow. The sensors and other instrumentation and control equipment must be carried by the tool. The tool must have a communication system capable of communicating with the surface, and data can be telemetered to the surface or stored in a downhole memory for later retrieval.
The method involves drilling or re-entering a bore hole and selecting an appropriate underground reservoir. The pressure, or some other characteristic of the fluid in the well bore at the reservoir, can then be measured. The extendable element, such as a packer or test probe, is set against the wall of the bore hole to isolate a portion of the bore hole or at least a portion of the bore hole wall. If two packers are used, this will create an upper annulus, a lower annulus, and an intermediate annulus within the well bore. The intermediate annulus corresponds to the isolated portion of the bore hole, and it is positioned at the reservoir to be tested. Next, the pressure, or other property, within the intermediate annulus is measured. The well bore fluid, primarily drilling mud, may then be withdrawn from the intermediate annulus with the pump. The level at which pressure within the intermediate annulus stabilizes may then be measured; it will correspond to the formation pressure.
Alternatively, a piston or other test probe can be extended from the test apparatus to contact the bore hole wall in a sealing relationship, or some other expandable element can be extended to create a zone from which essentially pristine formation fluid can be withdrawn. This could also be accomplished by extending a locating arm or rib from one side of the test tool, to force the opposite side of the test tool to contact the bore hole wall, thereby exposing a sample port to the formation fluid. Regardless of the apparatus used, the goal is to establish a zone of pristine formation fluid from which a sample can be taken, or in which characteristics of the fluid can be measured. This can be accomplished by various means. The example first mentioned above is to use inflatable packers to isolate a vertical portion of the entire bore hole, subsequently withdrawing drilling fluid from the isolated portion until it fills with formation fluid. The other examples given accomplish the goal by expanding an element against a spot on the bore hole wall, thereby directly contacting the formation and excluding drilling fluid.
Regardless of the apparatus used, it must be constructed so as to be protected during performance of the primary operations for which the work string is intended, such as drilling, re-entry, or workover. If an extendable probe is used, it can retract within the tool, or it can be protected by adjacent stabilizers, or both. A packer or other extendable elastomeric element can retract within a recession in the tool, or it can be protected by a sleeve or some other type of cover.
In addition to the pressure sensor mentioned above, the formation test apparatus can contain a resistivity sensor for measuring the resistivity of the well bore fluid and the formation fluid, or other types of sensors. The resistivity of the drilling fluid will be noticeably different from the resistivity of the formation fluid. If two packers are used, the resistivity of fluid being pumped from the intermediate annulus can be monitored to determine when all of the drilling fluid has been withdrawn from the intermediate annulus. As flow is induced from the isolated formation into the intermediate annulus, the resistivity of the fluid being pumped from the intermediate annulus is monitored. Once the resistivity of the exiting fluid differs sufficiently from the resistivity of the well bore fluid, it is assumed that formation fluid has filled the intermediate annulus, and the flow is terminated. This can also be used to verify a proper seal of the packers, since leaking of drilling fluid past the packers would tend to maintain the resistivity at the level of the drilling fluid.
After shutting in the formation, the pressure in the intermediate annulus can be monitored. Pumping can also be resumed, to withdraw formation fluid from the intermediate annulus at a measured rate. Pumping of formation fluid and measurement of pressure can be sequenced as desired to provide data which can be used to calculate various properties of the formation, such as permeability and size. If direct contact with the bore hole wall is used, rather than isolating a vertical section of the bore hole, similar tests can be performed by incorporating test chambers within the test apparatus. The test chambers can be maintained at atmospheric pressure while the work string is being drilled or lowered into the bore hole. Then, when the extendable element has been placed in contact with the formation, exposing a test port to the formation fluid, a test chamber can be selectively placed in fluid communication with the test port. Since the formation fluid will be at much higher pressure than atmospheric, the formation fluid will flow into the test chamber. In this way, several test chambers can be used to perform different pressure tests or take fluid samples.
In some embodiments which use two expandable packers, the formation test apparatus has contained therein a drilling fluid return flow passageway for allowing return flow of the drilling fluid from the lower annulus to the upper annulus. Also included is at least one pump, which can be a venturi pump or any other suitable type of pump, for preventing overpressurization in the intermediate annulus. Overpressurization can be undesirable because of the possible loss of the packer seal, or because it can hamper operation of extendable elements which are operated by differential pressure between the inner bore of the work string and the annulus. To prevent overpressurization, the drilling fluid is pumped down the longitudinal inner bore of the work string, past the lower end of the work string (which is generally the bit), and up the annulus. Then the fluid is channeled through return flow passageway and the venturi pump, creating a low pressure zone at the venturi, so that the fluid within the intermediate annulus is held at a lower pressure than the fluid in the return flow passageway.
The device may also include a circulation valve, for opening and closing the inner bore of the work string. A shunt valve can be located in the work string and operatively associated with the circulation valve, for allowing flow from the inner bore of the work string to the annulus around the work string, when the circulation valve is closed. These valves can be used in operating the test apparatus as a down hole blow-out preventor.
In the case where an influx of reservoir fluids invade the bore hole, which is sometimes referred to as a "kick", the method includes the steps of setting the expandable packers, and then positioning the circulating valve in the closed position. The packers are set at a position that is above the influx zone so that the influx zone is isolated. Next, the shunt valve is placed in the open position. Additives can then be added to the drilling fluid, thereby increasing the density of the mud. The heavier mud is circulated down the work string, through the shunt valve, to fill the annulus. Once the circulation of the denser drilling fluid is completed, the packers can be unseated and the circulation valve can be opened. Drilling may then resume.
An advantage of the present invention includes use of the pressure and resistivity sensors with the MWD system, to allow for real time data transmission of those measurements. Another advantage is that the present invention allows obtaining static pressures, pressure build-ups, and pressure draw-downs with the work string, such as a drill string, in place. Computation of permeability and other reservoir parameters based on the pressure measurements can be accomplished without pulling the drill string.
The packers can be set multiple times, so that testing of several zones is possible. By making measurement of the down hole conditions possible in real time, optimum drilling fluid conditions can be determined which will aid in hole cleaning, drilling safety, and drilling speed. When an influx of reservoir fluid and gas enter the well bore, the high pressure is contained within the lower part of the well bore, significantly reducing risk of being exposed to these pressures at surface. Also, by shutting-in the well bore immediately above the critical zone, the volume of the influx into the well bore is significantly reduced.
The novel features of this invention, as well as the invention itself, will be best understood from the attached drawings, taken along with the following description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional view of the apparatus of the present invention as it would be used with a floating drilling rig;
FIG. 2 is a perspective view of one embodiment of the present invention, incorporating expandable packers;
FIG. 3 is a sectional view of the embodiment of the present invention shown in FIG. 2;
FIG. 4 is a sectional view of the embodiment shown in FIG. 3, with the addition of a sample chamber;
FIG. 5 is a sectional view of the embodiment shown in FIG. 3, illustrating the flow path of drilling fluid;
FIG. 6 is a sectional view of a circulation valve and a shunt valve which can be incorporated into the embodiment shown in FIG. 3;
FIG. 7 is a sectional view of another embodiment of the present invention, showing the use of a centrifugal pump to drain the intermediate annulus; and
FIG. 8 is a schematic of the control system and the communication system which can be used in the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, a typical drilling rig 2 with a well bore 4 extending therefrom is illustrated, as is well understood by those of ordinary skill in the art. The drilling rig 2 has a work string 6, which in the embodiment shown is a drill string. The work string 6 has attached thereto a drill bit 8 for drilling the well bore 4. The present invention is also useful in other types of work strings, and it is useful with jointed tubing as well as coiled tubing or other small diameter work string such as snubbing pipe. FIG. 1 depicts the drilling rig 2 positioned on a drill ship S with a riser extending from the drilling ship S to the sea floor F.
If applicable, the work string 6 can have a downhole drill motor 10. Incorporated in the drill string 6 above the drill bit 8 is a mud pulse telemetry system 12, which can incorporate at least one sensor 14, such as a nuclear logging instrument. The sensors 14 sense down hole characteristics of the well bore, the bit, and the reservoir, with such sensors being well known in the art. The bottom hole assembly also contains the formation test apparatus 16 of the present invention, which will be described in greater detail hereinafter. As can be seen, one or more subterranean reservoirs 18 are intersected by the well bore 4.
FIG. 2 shows one embodiment of the formation test apparatus 16 in a perspective view, with the expandable packers 24, 26 withdrawn into recesses in the body of the tool. Stabilizer ribs 20 are also shown between the packers 24, 26, arranged around the circumference of the tool, and extending radially outwardly. Also shown are the inlet ports to several drilling fluid return flow passageways 36 and a draw down passageway 41 to be described in more detail below.
Referring now to FIG. 3, one embodiment of the formation test apparatus 16 is shown positioned adjacent the reservoir 18. The test apparatus 16 contains an upper expandable packer 24 and a lower expandable packer 26 for sealingly engaging the wall of the well bore 4. The packers 24, 26 can be expandable by any means known in the art. Inflatable packer means are well known in the art, with inflation being accomplished by means of injecting a pressurized fluid into the packer. Optional covers for the expandable packer elements may also be included to shield the packer elements from the damaging effects of rotation in the well bore, collision with the wall of the well bore, and other forces encountered during drilling, or other work performed by the work string.
A high pressure drilling fluid passageway 27 is formed between the longitudinal internal bore 7 and an expansion element control valve 30. An inflation fluid passageway 28 conducts fluid from a first port of the control valve 30 to the packers 24, 26. The inflation fluid passageway 28 branches off into a first branch 28A that is connected to the inflatable packer 26 and a second branch 28B that is connected to the inflatable packer 24. A second port of the control valve 30 is connected to a drive fluid passageway 29, which leads to a cylinder 35 formed within the body of the test tool 16. A third port of the control valve 30 is connected to a low pressure passageway 31, which leads to one of the return flow passageways 36. Alternatively, the low pressure passageway 31 could lead to a venturi pump 38 or to a centrifugal pump 53 which will be discussed further below. The control valve 30 and the other control elements to be discussed are operable by a downhole electronic control system 100 seen in FIG. 11, which will be discussed in greater detail hereinafter.
It can be seen that the control valve 30 can be selectively positioned to pressurize the cylinder 35 or the packers 24, 26 with high pressure drilling fluid flowing in the longitudinal bore 7. This can cause the piston 45 or the packers 24, 26 to extend into contact with the wall of the bore hole 4. Once this extension has been achieved, repositioning the control valve 30 can lock the extended element in place. It can also be seen that the control valve 30 can be selectively positioned to place the cylinder 35 or the packers 24, 26 in fluid communication with a passageway of lower pressure, such as the return flow passageway 36. If spring return means are utilized in the cylinder 35 or the packers 24, 26, as is well known in the art, the piston 45 will retract into the cylinder 35, and the packers 24, 26 will retract within their respective recesses. Alternatively, as will be explained below in the discussion of FIG. 7, the low pressure passageway 31 can be connected to a suction means, such as a pump, to draw the piston 45 within the cylinder 35, or to draw the packers 24, 26 into their recesses.
Once the inflatable packers 24, 26 have been inflated, an upper annulus 32, an intermediate annulus 33, and a lower annulus 34 are formed. This can be more clearly seen in FIG. 5. The inflated packers 24, 26 isolate a portion of the well bore 4 adjacent the reservoir 18 which is to be tested. Once the packers 24, 26 are set against the wall of the well bore 4, an accurate volume within the intermediate annulus 33 may be calculated, which is useful in pressure testing techniques.
The test apparatus 16 also contains at least one fluid sensor system 46 for sensing properties of the various fluids to be encountered. The sensor system 46 can include a resistivity sensor for determining the resistivity of the fluid. Also, a dielectric sensor for sensing the dielectric properties of the fluid, and a pressure sensor for sensing the fluid pressure may be included. A series of passageways 40A, 40B, 40C, and 40D are also provided for accomplishing various objectives, such as drawing a pristine formation fluid sample through the piston 45, conducting the fluid to a sensor 46, and returning the fluid to the return flow passageway 36. A sample fluid passageway 40A passes through the piston 45 from its outer face 47 to a side port 49. A sealing element can be provided on the outer face 47 of the piston 45 to ensure that the sample obtained is pristine formation fluid. This in effect isolates a portion of the well bore from the drilling fluid or any other contaminants or pressure sources.
When the piston 45 is extended from the tool, the piston side port 49 can align with a side port 51 in the cylinder 35. A pump inlet passageway 40B connects the cylinder side port 51 to the inlet of a pump 53. The pump 53 can be a centrifugal pump driven by a turbine wheel 55 or by another suitable drive device. The turbine wheel 55 can be driven by flow through a bypass passageway 84 between the longitudinal bore 7 and the return flow passageway 36. Alternatively, the pump 53 can be any other type of suitable pump. A pump outlet passageway 40C is connected between the outlet of the pump 53 and the sensor system 46. A sample fluid return passageway 40D is connected between the sensor 46 and the return flow passageway 36. The passageway 40D has therein a valve 48 for opening and closing the passageway 40D.
As seen in FIG. 4, there can be a sample collection passageway 40E which connects the passageways 40A, 40B, 40C, and 40D with the lower sample module, seen generally at 52. The passageway 40E leads to the adjustable choke means 74 and to the sample chamber 56, for collecting a sample. The sample collection passageway 40E has therein a chamber inlet valve 58 for opening and closing the entry into the sample chamber 56. The sample chamber 56 can have a movable baffle 72 for separating the sample fluid from a compressible fluid such as air, to facilitate drawing the sample as will be discussed below. An outlet passage from the sample chamber 56 is also provided, with a chamber outlet valve 62 therein, which can be a manual valve. Also, there is provided a sample expulsion valve 60, which can be a manual valve. The passageways from valves 60 and 62 are connected to external ports (not shown) on the tool. The valves 62 and 60 allow for the removal of the sample fluid once the work string 6 has been pulled from the well bore, as will be discussed below.
When the packers 24, 26 are inflated, they will seal against the wall of the well bore 4, and as they continue to expand to a firm set, the packers 24, 26 will expand slightly into the intermediate annulus 33. If fluid is trapped within the intermediate annulus 33, this expansion can tend to increase the pressure in the intermediate annulus 33 to a level above the pressure in the lower annulus 34 and the upper annulus 32. For operation of extendable elements such as the piston 45, it is desired to have the pressure in the longitudinal bore 7 of the drill string 6 higher than the pressure in the intermediate annulus 33. Therefore, a venturi pump 38 is used to prevent overpressurization of the intermediate annulus 33.
The drill string 6 contains several drilling fluid return flow passageways 36 for allowing return flow of the drilling fluid from the lower annulus 34 to the upper annulus 32, when the packers 24, 26 are expanded. A venturi pump 38 is provided within at least one of the return flow passageways 36, and its structure is designed for creating a zone of lower pressure, which can be used to prevent overpressurization in the intermediate annulus 33, via the draw down passageway 41 and the draw down control valve 42. Similarly, the venturi pump 38 could be connected to the low pressure passageway 31, so that the low pressure zone created by the venturi pump 38 could be used to withdraw the piston 45 or the packers 24, 26. Alternatively, as explained below in the discussion of FIG. 7, another type of pump could be used for this purpose.
Several return flow passageways can be provided, as shown in FIG. 2. One return flow passageway 36 is used to operate the venturi pump 38. As seen in FIG. 3 and FIG. 4, the return flow passageway 36 has a generally constant internal diameter until the venturi restriction 70 is encountered. As shown in FIG. 5, the drilling fluid is pumped down the longitudinal bore 7 of the work string 6, to exit near the lower end of the drill string at the drill bit 8, and to return up the annular space as denoted by the flow arrows. Assuming that the inflatable packers 24, 26 have been set and a seal has been achieved against the well bore 4, then the annular flow will be diverted through the return flow passageways 36. As the flow approaches the venturi restriction 70, a pressure drop occurs such that the venturi effect will cause a low pressure zone in the venturi. This low pressure zone communicates with the intermediate annulus 33 through the draw down passageway 41, preventing any overpressurization of the intermediate annulus 33.
The return flow passageway 36 also contains an inlet valve 39 and an outlet valve 80, for opening and closing the return flow passageway 36, so that the upper annulus 32 can be isolated from the lower annulus 34. The bypass passageway 84 connects the longitudinal bore 7 of the work string 6 to the return flow passageway 36.
Referring now to FIG. 6, yet another possible feature of the present invention is shown, wherein the work string 6 has installed therein a circulation valve 90, for opening and closing the inner bore 7 of the work string 6. Also included is a shunt valve 92, located in the shunt passageway 94, for allowing flow from the inner bore 7 of the work string 6 to the upper annulus 32. The remainder of the formation tester is the same as previously described.
The circulation valve 90 and the shunt valve 92 are operatively associated with the control system 100. In order to operate the circulation valve 90, a mud pulse signal is transmitted down hole, thereby signaling the control system 100 to shift the position of the valve 90. The same sequence would be necessary in order to operate the shunt valve 92.
FIG. 7 illustrates an alternative means of performing the functions performed by the venturi pump 38. The centrifugal pump 53 can have its inlet connected to the draw down passageway 41 and to the low pressure passageway 31. A draw down valve 57 and a sample inlet valve 59 are provided in the pump inlet passageway to the intermediate annulus and the piston, respectively. The pump inlet passageway is also connected to the low pressure side of the control valve 30. This allows use of the pump 53, or another similar pump, to withdraw fluid from the intermediate annulus 33 through valve 57, to withdraw a sample of formation fluid directly from the formation through valve 59, or to pump down the cylinder 35 or the packers 24, 26.
As depicted in FIG. 8, the invention includes use of a control system 100 for controlling the various valves and pumps, and for receiving the output of the sensor system 46. The control system 100 is capable of processing the sensor information with the downhole microprocessor/controller 102, and delivering the data to the communications interface 104, so that the processed data can then be telemetered to the surface using conventional technology. It should be noted that various forms of transmission energy could be used such as mud pulse, acoustical, optical, or electromagnetic. The communications interface 104 can be powered by a downhole electrical power source 106. The power source 106 also powers the flow line sensor system 46, the microprocessor/controller 102, and the various valves and pumps.
Communication with the surface of the Earth can be effected via the work string 6 in the form of pressure pulses or other means, as is well known in the art. In the case of mud pulse generation, the pressure pulse will be received at the surface via the 2-way communication interface 108. The data thus received will be delivered to the surface computer 110 for interpretation and display.
Command signals may be sent down the fluid column by the communications interface 108, to be received by the downhole communications interface 104. The signals so received are delivered to the downhole microprocessor/controller 102. The controller 102 will then signal the appropriate valves and pumps for operation as desired.
The down hole microprocessor/controller 102 can also contain a pre-programmed sequence of steps based on pre-determined criteria. Therefore, as the holdown hole data, such as pressure, resistivity, or dielectric constants, are received, the microprocessor/controller would automatically send command signals via the control means to manipulate the various valves and pumps.
OPERATION
In operation, the formation tester 16 is positioned adjacent a selected formation or reservoir. Next, a hydrostatic pressure is measured utilizing the pressure sensor located within the sensor system 46, as well as determining the drilling fluid resistivity at the formation. This is achieved by pumping fluid into the sample system 46, and then stopping to measure the pressure and resistivity. The data is processed down hole and then stored or transmitted up-hole using the MWD telemetry system.
Next, the operator expands and sets the inflatable packers 24, 26. This is done by maintaining the work string 6 stationary and circulating the drilling fluid down the inner bore 7, through the drill bit 8 and up the annulus. The valves 39 and 80 are open, and therefore, the return flow passageway 36 is open. The control valve 30 is positioned to align the high pressure passageway 27 with the inflation fluid passageways 28A, 28B, and drilling fluid is allowed to flow into the packers 24, 26. Because of the pressure drop from inside the inner bore 7 to the annulus across the drill bit 8, there is a significant pressure differential to expand the packers 24, 26 and provide a good seal. The higher the flow rate of the drilling fluid, the higher the pressure drop, and the higher the expansion force applied to the packers 24, 26. Alternatively, or in addition, another expandable element such as the piston 45 is extended to contact the wall of the well bore, by appropriate positioning of the control valve 30.
The upper packer element 24 can be wider than the lower packer 26, thereby containing more volume. Thus, the lower packer 26 will set first. This can prevent debris from being trapped between the packers 24, 26.
The venturi pump 38 can then be used to prevent overpressurization in the intermediate annulus 33, or the centrifugal pump 53 can be operated to remove the drilling fluid from the intermediate annulus 33. This is achieved by opening the draw down valve 41 in the embodiment shown in FIG. 3, or by opening the valves 82, 57, and 48 in the embodiment shown in FIG. 7.
If the fluid is pumped from the intermediate annulus 33, the resistivity and the dielectric constant of the fluid being drained can be constantly monitored by the sensor system 46. The data so measured can be processed down hole and transmitted up-hole via the telemetry system. The resistivity and dielectric constant of the fluid passing through will change from that of drilling fluid to that of drilling fluid filtrate, to that of the pristine formation fluid.
In order to perform the formation pressure build-up and draw down tests, the operator closes the pump inlet valve 57 and the by-pass valve 82. This stops drainage of the intermediate annulus 33 and immediately allows the pressure to build-up to virgin formation pressure. The operator may choose to continue circulation in order to telemeter the pressure results up-hole.
In order to take a sample of formation fluid, the operator could open the chamber inlet valve 58 so that the fluid in the passageway 40E is allowed to enter the sample chamber 56. Since the sample chamber 56 is empty and at atmospheric conditions, the baffle 72 will be urged downward until the chamber 56 is filled. An adjustable choke 74 is included for regulating the flow into the chamber 56. The purpose of the adjustable choke 74 is to control the change in pressure across the packers when the sample chamber is opened. If the choke 74 were not present, the packer seal might be lost due to the sudden change in pressure created by opening the sample chamber inlet valve 58.
Once the sample chamber 56 is filled, then the valve 58 can again be closed, allowing for another pressure build-up, which is monitored by the pressure sensor. If desired, multiple pressure build-up tests can be performed by repeatedly pumping down the intermediate annulus 33, or by repeatedly filling additional sample chambers. Formation permeability may be calculated by later analyzing the pressure versus time data, such as by a Horner Plot which is well known in the art. Of course, in accordance with the teachings of the present invention, the data may be analyzed before the packers 24 and 26 are deflated. The sample chamber 56 could be used in order to obtain a fixed, controlled drawn down volume. The volume of fluid drawn may also be obtained from a down hole turbine meter placed in the appropriate passageway.
Once the operator is prepared to either drill ahead, or alternatively, to test another reservoir, the packers 24, 26 can be deflated and withdrawn, thereby returning the test apparatus 16 to a standby mode. If used, the piston 45 can be withdrawn. The packers 24, 26 can be deflated by positioning the control valve 30 to align the low pressure passageway 31 with the inflation passageway 28. The piston 45 can be withdrawn by positioning the control valve 30 to align the low pressure passageway 31 with the cylinder passageway 29. However, in order to totally empty the packers or the cylinder, the venturi pump 38 or the centrifugal pump 53 can be used.
Once at the surface, the sample chamber 56 can be separated from the work string 6. In order to drain the sample chamber, a container for holding the sample (which is still at formation pressure) is attached to the outlet of the chamber outlet valve 62. A source of compressed air is attached to the expulsion valve 60. Upon opening the outlet valve 62, the internal pressure is released, but the sample is still in the sample chamber. The compressed air attached to the expulsion valve 60 pushes the baffle 72 toward the outlet valve 62, forcing the sample out of the sample chamber 56. The sample chamber may be cleaned by refilling with water or solvent through the outlet valve 62, and cycling the baffle 72 with compressed air via the expulsion valve 60. The fluid can then be analyzed for hydrocarbon number distribution, bubble point pressure, or other properties.
Once the operator decides to adjust the drilling fluid density, the method comprises the steps of measuring the hydrostatic pressure of the well bore at the target formation. Then, the packers 24, 26 are set so that an upper 32, a lower 34, and an intermediate annulus 33 are formed within the well bore. Next, the well bore fluid is withdrawn from the intermediate annulus 33 as has been previously described and the pressure of the formation is measured within the intermediate annulus 32. The other embodiments of extendable elements may also be used to determine formation pressure.
The method further includes the steps of adjusting the density of the drilling fluid according to the pressure readings of the formation so that the mud weight of the drilling fluid closely matches the pressure gradient of the formation. This allows for maximum drilling efficiency. Next, the inflatable packers 24, 26 are deflated as has been previously explained and drilling is resumed with the optimum density drilling fluid.
The operator would continue drilling to a second subterranean horizon, and at the appropriate horizon, would then take another hydrostatic pressure measurement, thereafter inflating the packers 24, 26 and draining the intermediate annulus 33, as previously set out. According to the pressure measurement, the density of the drilling fluid may be adjusted again and the inflatable packers 24, 26 are unseated and the drilling of the bore hole may resume at the correct overbalance weight.
The invention herein described can also be used as a near bit blow-out preventor. If an underground blow-out were to occur, the operator would set the inflatable packers 24, 26, and have the valve 39 in the closed position, and begin circulating the drilling fluid down the work string through the open valves 80 and 82. Note that in a blowout prevention application, the pressure in the lower annulus 34 may be monitored by opening valves 39 and 48 and closing valves 57, 59, 30, 82, and 80. The pressure in the upper annulus may be monitored while circulating directly to the annulus through the bypass valve by opening valve 48. Also the pressure in the internal diameter 7 of the drill string may be monitored during normal drilling by closing both the inlet valve 39 and outlet valve 80 in the passageway 36, and opening the by-pass valve 82, with all other valves closed. Finally, the by-pass passageway 84 would allow the operator to circulate heavier density fluid in order to control the kick.
Alternatively, if the embodiment shown in FIG. 6 is used, the operator would set the first and second inflatable packers 24, 26 and then position the circulation valve 90 in the closed position. The inflatable packers 24, 26 are set at a position that is above the influx zone so that the influx zone is isolated. The shunt valve 92 contained on the work string 6 is placed in the open position. Additives can then be added to the drilling fluid at the surface, thereby increasing the density. The heavier drilling fluid is circulated down the work string 6, through the shunt valve 92. Once the denser drilling fluid has replaced the lighter fluid, the inflatable packers 24, 26 can be unseated and the circulation valve 90 is placed in the open position. Drilling may then resume.
While the particular invention as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages hereinbefore stated, it is to be understood that this disclosure is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended other than as described in the appended claims.
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An apparatus and method are disclosed for obtaining samples of pristine formation fluid, using a work string designed for performing other downhole work such as drilling, workover operations, or re-entry operations. An extendable element extends against the formation wall to obtain the pristine fluid sample. While the test tool is in a standby condition, the extendable element is withdrawn within the work string, protected by other structure from damage during operation of the work string. The apparatus is used to sense downhole conditions while using a work string, and the measurements taken can be used to adjust working fluid properties without withdrawing the work string from the bore hole. When the extendable element is a packer, the apparatus can be used to prevent a kick from reaching the surface, adjust the density of the drilling fluid, and thereafter continuing use of the work string.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. application Ser. No. 11/730,788 filed Apr. 4, 2007, which is a continuation of U.S. application Ser. No. 10/990,527 filed on Nov. 18, 2004, now issued as U.S. Pat. No. 7,210,762, which is a continuation of U.S. application Ser. No. 10/803,922 filed on Mar. 19, 2004, now issued as U.S. Pat. No. 6,830,315, which is a continuation of U.S. application Ser. No. 09/609,140 filed on Jun. 30, 2000, now issued as U.S. Pat. No. 6,755,513 all of which are herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the field of ink jet printing systems, and more specifically to a support structure and ink supply arrangement for a printhead assembly and such printhead assemblies for ink jet printing systems.
DESCRIPTION OF THE PRIOR ART
[0003] Micro-electromechanical systems (“MEMS”), fabricated using standard VLSI semi-conductor chip fabrication techniques, are becoming increasingly popular as new applications are developed. Such devices are becoming widely used for sensing (for example accelerometers for automotive airbags), inkjet printing, micro-fluidics, and other applications. The use of semi-conductor fabrication techniques allows MEMS to be interfaced very readily with microelectronics. A broad survey of the field and of prior art in relation thereto is provided in an article entitled “The Broad Sweep of Integrated Micro-Systems”, by S. Tom Picraux and Paul McWhorter, in IEEE Spectrum, December 1998, pp. 24-33.
[0004] In PCT Application No. PCT/AU98/00550, the entire contents of which is incorporated herein by reference, an inkjet printing device has been described which utilizes MEMS processing techniques in the construction of a thermal-bend-actuator-type device for the ejection of a fluid, such as an ink, from a nozzle chamber. Such ink ejector devices will be referred to hereinafter as MEMJETs. The technology there described is intended as an alternative to existing technologies for inkjet printing, such as Thermal Ink Jet (TIJ) or “Bubble Jet” technology developed mainly by the manufacturers Canon and Hewlett Packard, and Piezoelectric Ink Jet (PIJ) devices, as used for example by the manufacturers Epson and Tektronix.
[0005] While TIJ and PIJ technologies have been developed to very high levels of performance since their introduction, MEMJET technology is able to offer significant advantages over these technologies. Potential advantages include higher speeds of operation and the ability to provide higher resolution than obtainable with other technologies. Similarly, MEMJET Technology provides the ability to manufacture monolithic printhead devices incorporating a large number of nozzles and of such size as to span all or a large part of a page (or other print surface), so that pagewidth printing can be achieved without any need to mechanically traverse a small printhead across the width of a page, as in typical existing inkjet printers.
[0006] It has been found difficult to manufacture a long TIJ printhead for full-pagewidth printing. This is mainly because of the high power consumption of TIJ devices and the problem associated therewith of providing an adequate power supply for the printhead. Similarly, waste heat removal from the printhead to prevent boiling of the ink provides a challenge to the layout of such printhead. Also, differential thermal expansion over the length of a long TIJ-printhead my lead to severe nozzle alignment difficulties.
[0007] Different problems have been found to attend the manufacture of long PIJ printheads for large- or full-page-width printing. These include acoustic crosstalk between nozzles due to similar time scales of drop ejection and reflection of acoustic pulses within the printhead. Further, silicon is not a piezoelectric material, and is very difficult to integrate with CMOS chips, so that separate external connections are required for every nozzle.
[0008] Accordingly, manufacturing costs are very high compared to technologies such as MEMJET in which a monolithic device may be fabricated using established techniques, yet incorporate very large numbers of individual nozzles. Reference should be made to the aforementioned PCT application for detailed information on the manufacture of MEMJET inkjet printhead chips; individual MEMJET printhead chips will here be referred to simply as printhead segments. A printhead assembly will usually incorporate a number of such printhead segments.
[0009] While MEMJET technology has the advantage of allowing the cost effective manufacture of long monolithic printheads, it has nevertheless been found desirable to use a number of individual printhead segments (CMOS chips) placed substantially end-to-end where large widths of printing are to be provided. This is because chip production yields decrease substantially as chip lengths increase, so that costs increase. Of course, some printing applications, such as plan printing and other commercial printing, require printing widths which are beyond the maximum length that is practical for successful printhead chip manufacture.
SUMMARY OF THE INVENTION
[0010] According to an aspect of the present disclosure, an inkjet printhead assembly includes an elongate support having a plurality of internal webs protruding from a base section to define a plurality of parallel ink supply channels; a shim mounted on the support and defining a plurality of rows of openings through which ink from respective supply channels is provided; and a plurality of elongate printhead modules mounted serially on the shim. Each module includes a carrier carrying a printhead. Each carrier defines a plurality of ink supply passages through which ink passes to the printhead from respective rows of the openings. Either end of each carrier defines complementary formations such that adjacent pairs of the carriers nest together. The plurality of internal webs protrude from the base section to define a semicircular recess in which the shim is received. The shim is received in the semicircular recess such that the each of the plurality of rows respectively align with one of the plurality of parallel ink channels.
BRIEF DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a perspective view of one embodiment of an inkjet printhead assembly according to the invention;
[0012] FIG. 2 is a perspective view of the inkjet printhead assembly shown in FIG. 1 , with a cover component (shield plate) removed;
[0013] FIG. 3 is an exploded perspective view of a part only of the inkjet printhead assembly shown in FIG. 1 ;
[0014] FIG. 4 is a perspective partial view of a support extrusion forming part of the inkjet printhead assembly shown in FIG. 3 ;
[0015] FIG. 5 is a perspective view of a sealing shim forming part of the inkjet printhead assembly shown in FIG. 3 ;
[0016] FIG. 6 is a perspective view of a printhead segment carrier shown in FIG. 3 ;
[0017] FIG. 7 is a further perspective view of the printhead segment carrier shown in FIG. 6 ;
[0018] FIG. 8 is a bottom elevation of the printhead carrier shown in FIGS. 6 and 7 (as viewed in the direction of arrow “X” in FIG. 6 );
[0019] FIG. 9 is a top elevation of the printhead carrier shown in FIGS. 6 and 7 (as viewed in the direction of arrow “Y” in FIG. 6 );
[0020] FIG. 10 is a cross-sectional view of the printhead carrier of FIGS. 6 and 7 taken at station “B-B” in FIG. 8 ;
[0021] FIG. 11 is a cross-sectional view of the printhead carrier of FIGS. 6 and 7 taken at station “A-A” in FIG. 8 ;
[0022] FIG. 11A is an enlarged cross-sectional view of the seating arrangement of a printhead segment at the print carrier as per detail “E” in FIG. 11 ;
[0023] FIG. 12 is a cross-sectional view of the printhead carrier of FIGS. 6 and 7 taken at station “D-D” in FIG. 8 ;
[0024] FIG. 13 is an external perspective view of an end cap of the inkjet printhead assembly shown in FIG. 1 ;
[0025] FIG. 14 is an internal perspective view of the end cap shown in FIG. 13
[0026] FIG. 15 is an external perspective view of a further end cap of the inkjet printhead assembly shown in FIG. 1 ;
[0027] FIG. 16 is an internal perspective view of the end cap shown in FIG. 15 ;
[0028] FIG. 17 is a perspective view (from the bottom) of the printhead assembly shown in FIG. 1 ;
[0029] FIG. 18 is a perspective view of a part assembly of a support profile and modified sealing shim which are alternatives to those shown in FIGS. 4 and 5 ;
[0030] FIG. 19 is a perspective view showing a molding tool and illustrating the basic arrangement of die components for injection molding of the printhead carrier shown in FIGS. 6 and 7 ;
[0031] FIG. 20 is a schematic cross-section of the injection molding tool shown in FIG. 19 , in an open position; and
[0032] FIG. 21 is a schematic transverse cross-section of the injection molding tool shown in FIG. 19 , in a closed position, taken at a station corresponding to the station “A-A” in FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] FIG. 1 shows in perspective view an inkjet printhead assembly 1 according to one aspect of the invention and, in phantom outline, a surface 2 on which printing is to be effected. In use, the surface 2 moves relative to the assembly 1 in a direction indicated by arrow 3 and transverse to the main extension of assembly 1 (this direction is hereinafter also referred to as the transverse direction of the assembly 1 ), so that elongate printhead segments 4 , in particular MEMJET printhead segments such as described in the above-mentioned PCT/AU98/00550, placed in stepped overlapping sequence along the lengthwise extension of assembly 1 can print simultaneously across substantially the entire width of the surface. The assembly 1 includes a shield plate 5 with which the surface 2 may come into sliding contact during such printing. Shield plate 5 has slots 6 , each corresponding to one of the printhead segments 4 , and through which ink ejected by that printhead segment 4 can reach surface 2 .
[0034] The particular assembly 1 shown in FIG. 1 has eleven printhead segments 4 , each capable of printing along a 2 cm printing length (or, in other words, within a printing range extending 2 cm) in a direction parallel to arrow 7 (hereinafter also called the lengthwise direction of the assembly 1 ) and is suitable for single-pass printing of a portrait A4-letter size page. However, this number of printhead segments 4 and their length are in no way limiting, the invention being applicable to printhead assemblies of varying lengths and incorporating other required numbers of printhead segments 4 .
[0035] The slots 6 and the printhead segments 4 are arranged along two parallel lines in the lengthwise direction, with the printing length of each segment 4 (other than the endmost segments 4 ) slightly overlapping that of its two neighboring segments 4 in the other line. The printing length of each of the two endmost segments 4 overlaps the printing length of its nearest neighbour in the other row at one end only. Thus printing across the surface 2 is possible without gaps in the lengthwise direction of the assembly. In the particular assembly shown, the overlap is approximately 1 mm at each end of the 2 cm printing length, but this figure is by no means limiting.
[0036] FIG. 2 shows assembly 1 with the shield plate 5 removed. Each printhead segment 4 is secured to an associated one printhead segment carrier 8 that will be described below in more detail. Also secured to each printhead segment 4 is a tape automated bonded (TAB) film 9 which carries signal and power connections (not individually shown) to the associated printhead segment 4 . Each TAB film 9 is closely wrapped around an extruded support profile 10 (whose function will be explained below) that houses and supports carriers 8 , and they each terminate onto a printed circuit board (PCB) 11 secured to the profile 10 on a side thereof opposite to that where the printhead segments 4 are mounted, see also FIG. 3 .
[0037] FIG. 3 shows an exploded perspective view of a part only of assembly 1 . In this view, three only of the printhead segment carriers 8 are shown numbered 8 a , 8 b and 8 c , and only the printhead segment 4 associated with printhead segment carrier 8 a is shown and numbered 4 a . The TAB film 9 associated therewith is terminated at one end on an outer face of the printhead segment 4 and is otherwise shown (for clarity purposes) in the unwound, flat state it has before being wound around profile 10 and connected to PCB 11 . As can be seen in FIG. 3 , printhead segment carriers 8 are received (and secured), together with an interposed sealing shim 25 , in a slot 21 of half-circular cross-sectional shape in profile member 10 as will be explained in more detail below.
[0038] FIG. 4 illustrates a cross-section of the profile member 10 (which is preferably an aluminium alloy extrusion). This component serves as a frame and/or support structure for the printhead segment carriers 8 (with their associated printhead segments 4 and TAB films 9 ), the PCB 11 and shield plate 5 . It also serves as an integral ink supply arrangement for the printhead segments 4 , as will become clearer later.
[0039] Profile member 10 is of semi-open cross-section, with a peripheral, structured wall 12 of uniform thickness. Free, opposing, lengthwise running edges 16 ′, 17 ′ of side wall sections 16 and 17 respectively of wall 12 border or delineate a gap 13 in wall 12 extending along the entire length of profile member 10 . Profile member 10 has three internal webs 14 a , 14 b , 14 c that stand out from a base wall section 15 of peripheral wall 12 into the interior of member 10 , so as to define together with side wall sections 16 and 17 a total of four (4) ink supply channels 20 a , 20 b , 20 c and 20 d which are open towards the gap 13 . The shapes, proportions and relative arrangement of the webs and wall sections 14 a - c , 16 , 17 are such that their respective free edges 14 a ′, 14 b ′, 14 c ′ and 16 ′, 17 ′, as viewed in the lengthwise direction and cross-section of profile member 10 , define points on a semi-circle (indicated by a dotted line at “a” in FIG. 4 ). In other words, an open slot 21 of semicircular cross-sectional shape is defined along one side of profile member 10 that runs along its extension, with each of the ink supply channels 20 a - d opening into common slot 21 .
[0040] Base wall section 15 of profile member 10 also includes a serrated channel 22 opening towards the exterior of member 10 , which, as best seen in FIG. 3 , serves to receive fastening screws 23 to fixedly secure PCB 11 onto profile member 10 in a form-fitting manner between free edges 24 (see FIG. 4 ) of longitudinally extending curved webs 107 extending from the base wall section 15 of profile member 10 .
[0041] Referring again to FIG. 3 , sealing shim 25 is received (and secured) within the half-circular open slot 21 . As best seen in FIGS. 3 and 5 , shim 25 includes four lengthwise extending rows of rectangular openings 26 that are equidistantly spaced in peripheral (widthwise) direction of shim 25 , so that three lengthwise-extending web sections 27 between the aperture rows (of which two are visible in FIG. 5 ) are located so as to be brought into abutting engagement against the free edges 14 a ′, 14 b ′ and 14 c ′ of webs 14 a , 14 b , 14 c of profile member 10 when shim 25 is received in slot 21 . As can be gleaned from FIG. 4 , the free edges 16 ′ and 17 ′ of side wall sections 16 , 17 of profile member 10 are shaped such as to provide a form-lock for retaining the lengthwise extending edges 28 of shim member 25 as a snap fit. In other words, once shim 25 is mounted in profile member 10 , it provides a perforated bottom for slot 21 , which allows passage of inks from the ink supply channels 20 a - d through apertures 26 in shim 25 into slot 21 . A glue or sealant is provided where shim webs 27 and edges 28 mate with the free edges 14 a ′, 14 b ′, 14 c ′, 16 ′ and 17 ′ of profile member 10 , thereby preventing cross-leakage between ink supply channels 20 a - d along the abutting interfaces between shim 25 and profile member 10 . It will be noted from FIG. 5 that not all apertures 26 have the same opening size. Reference numerals 26 ′ indicate two such smaller apertures, the significance of which is described below, which are present in each aperture row at predetermined aperture intervals. A typical size for the full-sized apertures 26 is 2 mm×2 mm. The shim is preferably of stainless steel, but a plastics sheet material may also be used.
[0042] Turning next to FIGS. 6-12 , these illustrate in different views and sections a typical printhead segment carrier 8 . Carrier 8 is preferably a single micro-injection molded part made of a suitable temperature and abrasion resistant and form-holding plastics material. (A further manufacturing operation is carried out subsequent to molding, as described below.) As best seen in FIGS. 6 and 7 , the overall external shape of carrier 8 can be described illustratively as a diametrically slit half cylinder, with a half-circular back face 91 , a partly planar front face 82 and stepped end faces 83 . FIG. 8 shows a plan view of back face 91 and FIG. 9 shows a plan view of front face 82 .
[0043] Carrier 8 has a plane of symmetry halfway along, and perpendicular to, its length, that is, as indicated by lines marked “b” in FIGS. 8 and 10 which lie in the plane. Line “b” as shown in FIG. 8 extends in a direction that will hereinafter be described as transverse to the carrier 8 . (When the carrier 8 is installed in the assembly 1 , this direction is the same as the transverse direction of the assembly 1 .) Lines marked “c” in FIGS. 8 , 9 , 11 and 12 together similarly indicate the position of an imaginary plane which lies between two sections of the carrier 8 of different length and whose overall cross-sectional shapes are quarter circles. Line “c” as shown in FIG. 9 extends in a direction that will hereinafter be described as lengthwise in the carrier 8 . (When the carrier 8 is installed in the assembly 1 this direction is the same as the lengthwise direction of the assembly 1 .) These sections will hereinafter be referred to as the shorter and longer “quarter cylinder” sections 8 ′ and 8 ″, respectively, to allow referenced description of features of the carrier 8 .
[0044] Each stepped end face 83 includes respective outer faces 84 ′ and 85 ′ of quarter-circular-sector shaped end walls 84 and 85 and an outer face 86 ′ of an intermediate step wall 86 between and perpendicular to end walls 84 , 85 . This configuration enables carriers 8 to be placed in the slot 21 of profile 10 in such a way that adjoining carriers 8 overlap in the lengthwise direction with the step walls 86 of pairs of neighbouring carriers 8 facing each and overlapping. Such an “interlocking” arrangement is shown in FIG. 2 , wherein it is apparent that every one of the eleven (11) carriers 8 has an orientation, relative to its neighbouring carrier or carriers 8 , such that faces 84 ′ and 85 ′ of each carrier lie adjacent to faces 85 ′ and 84 ′, respectively, of its neighbouring carrier(s) 8 . In other words, each carrier 8 is so oriented in relation to its neighbouring carrier(s) as to be rotated relatively by 180° about an axis perpendicular to the face 82 . In essence, neighbouring carriers 8 will align along a common lengthwise-oriented plane defined between the step walls 86 of adjoining carriers 8 , shorter and longer quarter cylinder sections 8 ′ and 8 ″ of adjoining carriers 8 alternating with one another along the extension of slot 21 .
[0045] Turning now in particular to FIGS. 7 , 9 , 11 and 11 a , front face 82 of carrier 8 includes on the shorter quarter cylinder section 8 ′ a planar surface 81 . Formed in surface 81 are two handling (i.e. pick-up) slots 87 whose purpose is described below. On the longer quarter cylinder section 8 ″, front face 82 incorporates a mounting or support surface 88 recessed with respect to edges 89 of sector-shaped end walls 84 that are co-planar with the surface 81 . As best seen in FIG. 11 , mounting surface 88 recedes in slanting fashion from a point on the back face 91 of the longer quarter cylinder section 8 ″ towards an elongate recess 90 extending lengthwise between walls 84 . Recess 90 is of constant transverse cross-section along its length and is shaped to receive in form-fitting manner one printhead segment 4 . FIG. 11 a shows, schematically only, printhead segment 4 in position in recess 90 . Mounting surface 88 is provided to accommodate in flush manner with respect to the surface 81 the terminal end of TAB film 9 connected to printhead segment 4 , as is best seen in FIG. 3 . Due to the opposing orientations of neighbouring carriers 8 along the extension of assembly 1 , the TAB films 9 associated with any two neighbouring carriers 8 lead away from their respective segments 4 in opposite transverse directions, as can be seen in FIG. 2 .
[0046] Referring now to FIGS. 6 , 7 , 8 , 10 and 11 in particular, four rows of ink galleries or ink supply passages 92 a to 92 d of generally quadrilateral cross-section are formed within the printhead segment carrier 8 . The ink galleries 92 a to 92 d act as conduits for ink to pass from the ink supply passages 20 a to 20 d , respectively, via openings 26 in the shim 25 , to the printhead segment 4 mounted in recess 90 of the printhead segment carrier 8 . Galleries 92 a - 92 d extend in quasi-radial arrangement between the half-cylindrical back face 91 of carrier 8 and recess 90 located in the longer quarter cylinder section 8 ″ at front face 82 . The expression “quasi-radial” is used here because recess 90 is not located at a transversely central position across carrier 8 , but is offset into the longer quarter cylinder section 8 ″, so that the inner ends of galleries 92 a - 92 d are similarly off-set, as further described below. Each gallery 92 has a rectangular opening 93 at back face 91 . All rectangular openings 93 have the same dimension in a peripheral direction of face 91 and are equidistantly spaced around the periphery of back face 91 . Moreover, the openings 93 are symmetrically located on opposing sides of the boundary between shorter quarter cylinder section 8 ′ and longer quarter cylinder section 8 ″, as represented in FIG. 11 by the line marked “c”. All openings 93 in the shorter quarter cylinder section 8 ′ are of the same dimension, and equispaced, in the lengthwise direction. This also applies to the openings 93 in the longer quarter cylinder section 8 ″, except that openings 93 ′ in the longer quarter cylinder section 8 ″ which correspond to endmost galleries 92 a ′ and 92 b ′ are of smaller dimension in the lengthwise direction than the other galleries 92 a and 92 b , respectively.
[0047] By way of further description of how the galleries 92 a to 92 d are formed, printhead segment carrier 8 includes a set of five (5) quasi-radially converging walls 95 which converge from back face 91 towards recess 90 at front face 82 and two of which define the faces 81 and 88 . The walls 95 perpendicularly intersect seven (7) generally semi-circular and mutually parallel walls 97 that are equidistantly spaced apart in lengthwise extension of carrier 8 . Of walls 97 , the two endmost ones extending into the shorter quarter cylinder section 8 ′ provide the end walls 85 of stepped end faces 83 , thereby defining twenty-four (24) quasi-radially extending ink galleries 92 a to 92 d , of quadrilateral cross-section, in four lengthwise-extending rows each of six galleries. The walls 97 are parallel to and lie between end walls 84 .
[0048] FIG. 12 shows a cross-section through one of the lengthwise end portions of longer quarter cylinder section 8 ″ of carrier 8 . By comparison with FIG. 11 (which shows a cross-section through the main body of carrier 8 ), it will be seen that the quasi-radially extending walls 95 bordering end gallery 92 a ′ have the same shape as walls 95 which border galleries 92 a , whereas gallery 92 b ′ is bounded on one side by intermediate step wall 86 and by a wall 108 . FIG. 12 also shows a wall 111 and a wall formation 112 on the wall 86 , the purpose of which is explained below.
[0049] Converging walls 95 are so shaped at their radially inner ends as to define four ink delivery slots 96 a to 96 d which extend lengthwise in the carrier 8 and which open into the recess 90 , as best seen in FIGS. 11 and 11 a . The slots 96 a to 96 d extend between the opposite end walls 84 of longer quarter cylinder section 8 ″ and pierce through the inner parallel walls 97 , including the endwise opposite walls 97 which form the end walls 85 of the shorter cylinder section 8 ′. FIG. 12 shows how slots 96 a to 96 d extend and are formed within the end portions of the longer quarter cylinder section 8 ″, where the slots 96 a to 96 d are defined by the terminal ends of two of walls 95 , walls 108 , 111 and wall formation 112 , wall formation 112 in effect being a perpendicular lip of intermediate step wall 86 .
[0050] The widths and transverse positioning of the ink delivery slots 96 a to 96 d are such that when a printhead segment 4 is received in recess 90 , a respective one of the slots 96 a - 96 d will be in fluid communication with one only of four lengthwise oriented rows of ink supply holes 41 on rear face 42 of printhead segment 4 , compare FIG. 11 a . Each row of ink supply holes 41 corresponds to a row of printhead nozzles 43 running lengthwise along the front face 44 of printhead segment 4 . In the schematic representation of segment 4 in FIG. 11 a , the positions of holes 41 and nozzles are indicated by dots, with no attempt made to show their actual construction. Reference to PCT Application No. PCT/AU98/00550 will provide further details of the make-up of segment 4 . Accordingly, each of the ink galleries of a specific gallery row 92 a to 92 d is in fluid communication with one only of the rows of ink supply holes 41 . Once a printhead segment 4 is form fittingly received in recess 90 and sealingly secured with its rear face 42 against the terminal inner ends of walls 95 , and wall formations 108 , 111 and 112 (using a suitable sealant or adhesive), cross-communication and ink bleeding between slots 96 a - 96 d via recess 90 is not possible.
[0051] When a carrier 8 is installed in its correct position lengthwise in the slot 21 of profile 10 , compare FIG. 3 , each opening 93 in its back face 91 aligns with one of the openings 26 in the shim 25 . Smaller openings 26 ′ in the shim 25 correspond to openings 93 ′ of the smaller galleries 92 a ′ and 92 b ′ of carrier 8 . Therefore, each one of the ink supply channels 20 a to 20 d is in fluid communication with one only of the rows of ink galleries 92 a to 92 d , respectively, and so with one only of the slots 96 a to 96 d respectively and only one of the rows of ink supply holes 41 . A suitable glue or sealant is provided at mating surfaces of the shim 25 and the carrier 8 to prevent leakage of ink from any of the channels 20 a to 20 d to an incorrect one of the galleries 92 , as described further below. The symmetrical location (mentioned above) of openings 93 on back face 91 of carrier 8 , which is matched by the openings 26 in shim 25 , enables the carrier 8 to be received in the slot 21 in either of the two orientations shown in FIG. 3 , with in both cases each row of ink galleries 92 a to 92 d aligning with one only of the ink supply channels 20 a to 20 d.
[0052] As mentioned above, the longer quarter cylinder section 8 ″ of carrier 8 has two galleries 92 a ′ and 92 b ′ at each lengthwise end that have no counterpart in the shorter section 8 ′. These galleries 92 a ′ and 92 b ′ provide direct ink supply paths to that part of their associated ink delivery slots 96 a and 96 b located in the longer quarter cylinder section 8 ″, and thus to the ink supply holes 41 of the printhead segment 4 that are located near the lengthwise terminal ends of segment 4 when secured within recess 90 . There are no corresponding quasi-radial galleries to supply ink to the end regions of the slots 96 c and 96 d . However, it is desirable to provide direct ink supply to the end portions of the other two slots 96 c and 96 d as well, without reliance on lengthwise flow within the slots 96 c and 96 d of ink that has passed through galleries 92 c and 92 d respectively. This is ensured by provision of ink supply chambers 99 c and 99 d which are shown in FIG. 12 and which supply ink to the slots 96 c and 96 d , respectively. Chambers 99 c and 99 d are bounded by the walls 84 , 86 , and wall formations 108 , 111 and 112 , are open towards slots 96 c and 96 d , respectively, and are in fluid communication through holes 113 and 114 in an endmost wall 97 with endmost ones of ink galleries 92 c and 92 d , respectively. The holes 113 and 114 have outlines shaped to match the transverse cross-sectional shapes of the chambers 99 c and 99 d , respectively, as shown in FIG. 12 , and the means whereby holes 113 and 114 are formed is described below.
[0053] FIGS. 13 and 14 show a first end cap 50 which is sealingly secured to an open terminal longitudinal end of profile member 10 , as may be seen in FIGS. 1 and 2 . Cap 50 is molded from a plastics material and it incorporates a generally planar wall portion 51 that extends perpendicularly to a lengthwise axis of profile member 10 . Four tubular stubs 55 a - 55 d are integrally moulded with planar wall portion 51 on side 52 of wall portion 51 which will face away from support profile 10 when end cap 50 is secured thereto. On the planar wall side 53 which will face the longitudinal terminal end of support profile 10 (see FIG. 14 ), four hollow-shaped stubs 57 a - 57 d are integrally moulded with planar wall portion 51 . As best seen in FIG. 14 , ink supply conduits 56 a to 56 d are defined within tubular stubs 55 a to 55 d respectively, extend through planar wall portion 51 , and open within shaped stubs 57 a to 57 d , respectively, located on the other sides of cap 50 .
[0054] The shape of each one of the insert stubs 57 a to 57 d , as seen in transverse cross-section, corresponds respectively to one of the ink supply channels 20 a to 20 d of support profile so that, when cap 50 is secured to the terminal axial end of support profile 10 , the walls of stubs 57 a - 57 d are received form-fittingly in ink supply channels 20 a - 20 d to prevent cross-migration of ink therebetween. The face 53 abuts a terminal end face of the profile 10 . Preferably, glue or a sealant can be applied to the mating surfaces of profile 10 and cap 50 to enhance the sealing function.
[0055] The tubular stubs 55 a - 55 d serve as female connectors for pliable/flexible ink supply hoses (not illustrated) that can be connected thereto sealingly, thereby to supply ink to the integral ink supply channels 20 a - 20 d of support profile 10 .
[0056] A further stub 58 , D-shaped in transverse cross-section, is integrally molded to planar wall portion 51 at side 53 . In completed assembly 1 , the curved wall 71 , semi-circular in transverse cross-section, of retaining stub 58 seals against the inside surface of shim 25 , with the terminal edge of shim 25 abutting a peripheral ridge 72 around the stub 58 . Preferably, to avoid cross-migration of ink among channels 20 a to 20 d , an adhesive or sealant is provided between the shim 25 and wall 71 . The stub 58 assists in retaining the shim 25 in slot 21 .
[0057] A second end cap 60 , which is shown in FIGS. 15 and 16 , is mounted to the other end of the profile 10 opposite to cap 50 . Cap 60 has insert stubs 67 a to 67 d and a retaining stub 68 identical in arrangement and shape to stubs 57 a to 57 d and stub 58 , respectively, of end cap 50 . Insert stubs 67 a to 67 d and retention stub 68 are integrally molded with a planar wall portion 61 , and in the completed assembly 1 seal off the individual ink supply channels 20 a - 20 d from one another, to prevent cross-migration of ink among them. Wall 77 of the retention stub 68 abuts the shim 25 in the same way as described above. A sealant or adhesive is preferably used with end cap 60 in the same way (and for the same purpose) as described above in respect of end cap 50 .
[0058] Whereas end cap 50 enables connection of ink supply hoses to the printhead assembly 1 , end cap 60 has no tubular stubs on exterior face 62 of planar wall portion 61 . Instead, four tortuous grooves 65 a to 65 d are formed on exterior face 62 , and terminate at holes 66 a to 66 d , respectively, extending through wall portion 61 . Each one of holes 66 a to 66 d opens into a respective one of the channels 20 a to 20 d so that when the cap 60 is in place on the profile 10 , each one of the grooves 65 a to 65 d is in fluid communication with a respective one of the channels 20 a to 20 d . The grooves 65 a - 65 d permit bleeding-off of air during priming of the printhead assembly 1 with ink, as holes 66 a - 66 d permit air expulsion from the ink supply channels 20 a - 20 d of support profile 10 via grooves 65 a - 65 d . Grooves 65 a - 65 d are capped under a translucent plastic film 69 bonded to outer face 62 . Translucent plastic film 69 thus also serves the purpose of allowing visual confirmation that the ink supply channels 20 a - 20 d of profile 10 are properly primed. For charging the ink supply channels 20 a - 20 d with ink, film 69 is folded back (as shown in FIG. 15 ) to partially uncover grooves 65 a - 65 d , so that displaced air may bleed out as ink enters the grooves 65 a - 65 d through holes 66 a - 66 d . When ink is visible behind film 69 in each groove 65 a - 65 d , film 69 is folded towards face 62 and bonded against face 62 to sealingly cover face 62 and so cap-off grooves 65 a - 65 d and isolate them from one another.
[0059] Referring to FIG. 17 (and see also FIGS. 3 and 4 ), the printed circuit board (PCB) 11 locates between edges 24 formed on profile 10 , and is secured by screw fasteners 23 which engage with the serrations in elongate channel 22 of support profile 10 . The PCB 11 contains three surface mounted halftoning chips 73 , a data connector 74 , printhead power and ground busbars 75 and decoupling capacitors 76 . Side walls 16 , 17 of support profile 10 are rounded near the edges 24 to avoid damage to the TAB films 9 when these are wound about profile 10 . The electronic components 73 and 76 are specific to the use of MEMJET chips as the printhead segments 4 , and would of course, if other another printhead technology were to be used, be substituted with other components as necessitated by that technology.
[0060] The shield plate 5 illustrated in FIG. 1 , which is a thin sheet of stainless steel, is bonded with sealant such as a silicon sealant onto the printhead segment carriers 8 . The shield plate 5 shields the TAB films 9 and the printhead segments 4 from physical damage and also serves to provide an airtight seal around the printhead segments 4 when the assembly 1 is capped during idle periods.
[0061] The multi-part layout of the printhead assembly 1 that has been described in detail above has the advantage that the printhead segment carriers 8 , which interface directly with the printhead segments 4 and which must therefore be manufactured with very small tolerances, are separate from other parts, including particularly the main support frame (profile 10 ) which may therefore be less tightly toleranced. As noted above, the printhead segment carriers 8 are precision injection micro-moldings. Moldings of the required size and complexity are obtainable using existing micromolding technology and plastics materials such as ABS, for example. Tolerances of +/−10 microns on specified dimensions are achievable including the ink supply grooves 96 a - 96 d , and their relative location with respect to the recess 90 in which the printhead segments 4 are received. Such tolerances are suitable for this application. Other material selection criteria are thermal stability and compatibility with other materials to be used in the assembly 1 , such as inks and sealants. The profile 10 is preferably an aluminum alloy extrusion. Tolerances specified at +/−100 microns have been found suitable for such extrusions, and are achievable as well.
[0062] FIGS. 19 , 20 and 21 are schematic representations only, intended to provide an understanding of the construction of an injection molding die used in the manufacture of a printhead segment carrier 8 . A multi-part die 100 is used, having a fixed base die part 104 , which in use defines the face 82 , recess 90 and slots 96 a to 96 d of the carrier 8 , and a multi-part upper die part 102 . The upper die part 102 is closed against the base part 104 for molding, and includes a part 101 with multiple fingers 101 a which in use form the galleries 92 b (including galleries 92 b ′) and parts 106 which are fixed relative to part 101 . Also included in the upper part 102 are die parts 103 which are movable relative to the part 101 and which have fingers 103 a to form the remaining galleries 92 a , 92 c and 92 d . Parts 103 seat against parts 106 when molding is underway. Spaces between the fingers 101 a and 103 a correspond to the walls 97 . In use of the die 100 , terminal tips of the fingers 101 a and 103 a close against blades 105 which in use form the ink supply slots 96 a - 96 d of carrier 8 and which are mounted to male base 104 to be detachable and replaceable when necessary. Base die part 104 also has inserts 104 a which in use form the pickup slots 87 . Because zero draft is preferred on the stepped end faces 83 in this application, the die 100 also has two movable end pieces (not shown, for clarity) which in use of the die 100 are movable generally axially to close against the upper die part 102 and which are shaped to define the end faces 84 ′, 85 ′ and 86 ′ of carrier 8 . FIG. 21 shows a schematic transverse cross-section of the mold 100 when closed, with areas in black corresponding to the carrier 8 being molded.
[0063] As was mentioned above, the two opposite end portions of the larger quarter cylinder section of carrier 8 incorporate two ink supply chambers 99 c and 99 d (see FIG. 12 ) to provide ink to the ink supply slots 96 c and 96 d in that region of the carrier 8 . These chambers 99 c and 99 d and associated communication holes 113 and 114 in parallel walls 97 that lead into the neighbouring galleries 92 c and 92 d , are formed in an operation subsequent to molding, by laser cutting openings of the required shape in the end walls 84 and the neighbouring inner parallel walls 97 from each end. The openings cut in end walls 84 are only necessary so as to access the inner walls 97 , and are therefore subsequently permanently plugged using appropriately shaped plugs 115 as shown in FIG. 6 .
[0064] Extrusions usable for profile 10 can be produced in continuous lengths and precision cut to the length required. The particular support profile 10 illustrated is 15.4 mm×25.4 mm in section and about 240 mm in length. These dimensions, together with the layout and arrangement of the walls 16 and 17 and internal webs 14 a to 14 c , have been found suitable to ensure adequate ink supply to eleven (11) MEMJET printhead segments 4 carried in the support profile to achieve four-color printing at 120 pages per minute (ppm). Support profiles with larger cross-sectional dimensions can be employed for very long printhead assemblies and/or for extremely high-speed printing where greater volumes of ink are required. Longer support profiles may of course be used, but are likely to require cross-bracing and location into a more rigid chassis to avoid alignment problems of individual printhead segments, for example in the case of a wide format printer of 54″ (1372 mm) or more.
[0065] An important step in manufacturing (and assembling) the assembly 1 is achieving the necessary, very high level of precision in relative positioning of the printhead segments 4 , and here too the construction of the assembly 1 as described above is advantageous. A suitable manufacturing sequence that ensures such high relative positioning of printheads on the support profile will now be described.
[0066] After manufacture and successful testing of an individual printhead segment 4 , its associated TAB film 9 is bumped and then bonded to bond pads along an edge of the printhead segment 4 . That is, the TAB film is physically secured to segment 4 and the necessary electrical connections are made. The terms “bumped” and “bonded” will be familiar to persons skilled in the arts where TAB films are used. The printhead carrier 8 is then primed with adhesive on all those surfaces facing into recess 90 that mate and must seal with the printhead segment 4 , see FIG. 11 a , i.e. along the length of the radially-inner edges of walls 95 , 108 and 111 , the face of formation 112 and on inner faces of walls 84 . The printhead segment 4 is then secured in place in recess 90 with its TAB film 9 attached. Extremely accurate alignment of the printhead segment 4 within recess 90 of printhead segment carrier 8 is not necessarily required (but is preferred), because relative alignment of all segments 4 at the support profile 10 is carried out later, as is described below. The assembly of the printhead segment 4 , printhead segment carrier 8 and TAB film 9 is preferably tested at this point for correct operation using ink or water, before being positioned for placement in the slot 21 of support profile 10 .
[0067] The support profile 10 is accurately cut to length (where it has been manufactured in a length longer than that required, for example by extrusion), faced and cleaned to enable good mating with the end caps 50 and 60 .
[0068] A glue wheel is run the entire length of semi-circular slot 21 , priming the terminal edges 14 a ′, 14 b ′, 14 c ′ of webs 14 a - 14 c and edges 16 ′, 17 ′ of profile side walls 16 , 17 with adhesive that will bond the sealing shim 25 into place in slot 21 once sealing shim 25 is placed into it with preset distance from its terminal ends (+/−10 microns). The shim 25 is snap-fitted into place at edges 16 ′, 17 ′ and the glue is allowed to set. Next, end caps 50 and 60 are bonded into place whereby (ink channel sealing) insert stubs 57 a - 57 d and 67 a - 67 d are received in ink channels 20 a - 20 d of profile 10 , and faces 71 and 77 of retention stubs 58 and 68 , respectively, lie on shim 25 . This sub-assembly provides a chassis in which to successively place, align and secure further sub-assemblies (hereinafter called “carrier subassemblies”) each consisting of a printhead segment carrier 8 with its respective printhead segment 4 and TAB film 9 already secured in place thereon.
[0069] A first carrier sub-assembly is primed with glue on the back face 91 of its printhead segment carrier 8 . At least the edges of walls 95 and 86 are primed. A glue wheel, running lengthwise, is preferably used in this operation. After priming with glue, the carrier sub-assembly is picked up by a manipulator arm engaging into pick-up slots 87 on front face 82 of carrier 8 and placed next to the stub 58 of end cap 50 (or the stub 68 of cap 60 ) at one end of slot 21 in profile 10 . The glue employed is of slow-setting or heat-activated type, thereby to allow a small level of positional manipulation of each carrier subassembly, lengthwise in the slot 21 , before final setting of the glue. With the first carrier subassembly finally secured to the shim 25 within the slot 21 , a second carrier sub-assembly is then picked up, primed with glue as above, and placed in a 180-degree-rotated position (as described above, and as may be seen in FIG. 3 ) next to the first carrier sub-assembly onto shim 25 and within the slot 21 . The second carrier sub-assembly is then positioned lengthwise so that there is correct lengthwise relative positioning of its printhead segment 4 and the segment 4 of the previously-placed segment 4 , as determined using suitable fiducial marks (not shown) on the exposed front surface 44 of each of the printhead segments 4 . That is, lengthwise alignment is carried out between successive printhead segments 4 , even though it is the printhead segment carrier 8 that is actually manipulated. This relative alignment is carried out to such (sub-micron) accuracy as is required to match the printing resolution capability of the printhead segments 4 . Finally, the bonding of the second carrier sub-assembly to shim 25 is completed. The above process is then repeated with further carrier sub-assemblies being successively positioned, aligned, and bonded into place, until all carrier subassemblies are in position within the slot 21 and bonded in their correct positions.
[0070] The shield plate 5 has a thin film of silicon sealant applied to its underside and is mated to the printhead segment carriers 8 and TAB films 9 along the entire length of the printhead assembly 1 . By suitable choice of adhesive properties of the silicon sealant, the shield plate 5 can be made removable to enable access to the printhead segment carriers 8 , printhead segments 4 and TAB films 9 for servicing and/or exchange.
[0071] A sub-assembly of PCB 11 and printhead control and ancillary components 73 to 76 is secured to profile 10 using four screws 23 . The TAB films 9 are wrapped around the exterior walls 16 , 17 of profile 10 and are bumped and bonded (i.e. physically and electrically connected) to the PCB 11 . See FIG. 17 .
[0072] Finally, the completed assembly 1 is connected at the ink inlet stubs 55 a - d of end cap 50 to suitable ink supplies, primed as described above and sealed using sealing film 69 of end cap 60 . Power and signal connections are completed and the inkjet printhead assembly 1 is ready for final testing and subsequent use.
[0073] It will be apparent to persons skilled in the art that many variations of the above-described assembly and components are possible. For example, FIG. 18 shows a shim 125 that is substantially the same as shim 25 , including having openings 126 and 126 ′ corresponding to the openings 26 and 26 ′ in shim 25 , save for longitudinally extending rim webs 128 which, when the shim 125 is mounted to a support profile 110 , abut in surface-engaging manner against the outside of the terminal ends of side walls 116 , 117 of profile 110 instead of being snap-fittingly received between them as is the case with shim 25 . This arrangement permits wider tolerances to be used in the manufacture of the support profile 110 without compromising the mating capability of the shim 125 and the profile 110 .
[0074] In yet another possible arrangement, the shim 25 could be eliminated entirely, with the printhead segment carriers 8 then bearing and sealing directly on the edges 14 a ′- 14 c ′ and 16 ′, 17 ′ of the webs 14 a - 14 c and side walls 16 , 17 at slot 21 of support profile 10 .
[0075] It will be appreciated by persons skilled in the art that still further variations and modifications may be made without departing from the scope of the invention. The embodiments of the present invention as described above are in no sense intended to be restrictive.
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An inkjet printhead assembly includes an elongate support having a plurality of internal webs protruding from a base section to define a plurality of parallel ink supply channels; a shim mounted on the support and defining a plurality of rows of openings through which ink from respective supply channels is provided; and a plurality of elongate printhead modules mounted serially on the shim. Each module includes a carrier carrying a printhead. Each carrier defines a plurality of ink supply passages through which ink passes to the printhead from respective rows of the openings. Either end of each carrier defines complementary formations such that adjacent pairs of the carriers nest together. The plurality of internal webs protrude from the base section to define a semicircular recess in which the shim is received. The shim is received in the semicircular recess such that the each of the plurality of rows respectively align with one of the plurality of parallel ink channels.
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PRIORITY CLAIM & INCORPORATION BY REFERENCE
This application is 1) a divisional of U.S. patent application Ser. No. 13/089,312 filed Apr. 19, 2011 and entitled VALVE WITH SHUTTLE which is 2) a continuation-in-part of U.S. patent application Ser. No. 12/766,141 filed Apr. 23, 2010 and entitled VALVE WITH SHUTTLE FOR USE IN A FLOW MANAGEMENT SYSTEM, now U.S. Pat. No. 8,545,190. These U.S. patent application Ser. Nos. 13/089,312 and 12/766,141 are incorporated herein, in their entireties and for all purposes.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for managing a fluid flow. In particular, the system includes a valve with a shuttle for managing a fluid flow.
2. Discussion of the Related Art
Pumps and valves located in hard to reach places present maintenance and maintenance downtime issues. Where pumps and valves are used to produce a natural resource such as a hydrocarbon, downtime can result in lost production and increased expenses for workmen and materials.
In particular, downhole production strings including pumps and valves for lifting fluids such as particulate laden liquids and slurries present a maintenance problem. Here, both pumps and valves can lose capacity and in cases be rendered inoperative when conditions including fluid conditions and fluid velocities fall outside an intended operating range. Such unintended operating conditions can foul, plug, and damage equipment.
Despite the industry's resistance to change, there remains a need to improve production strings.
SUMMARY OF THE INVENTION
The present invention includes a valve with a shuttle and is intended for use in a flow management system.
In an embodiment, a valve body includes a spill port and a shuttle is located in a chamber of the valve body. The shuttle has a through hole extending between a shuttle closure end and a shuttle spring end. A first seat and a first seat closure are located in the through hole. Second and third seats are located in the valve body chamber and second and third seat closures are located on the shuttle closure end. A spring is located substantially between the shuttle spring end and a fixture coupled to the valve body. The valve is operable to pass a flow entering the through hole at the shuttle spring end and to spill a flow that closes the first seat closure. In some embodiments, the circumference of the second seat is greater than the circumference of the third seat and the circumference of the shuttle spring end is more than two times greater than the circumference of the third seat.
In an embodiment, a valve body includes a spill port and a shuttle located in a chamber of the valve body. The shuttle has a through hole extending between a shuttle closure end and a shuttle spring end. A valve center line is shared by the valve body and the shuttle. A first seat is located on a first face of the shuttle and there is a first seat closure. The first seat closure has a central bore for accepting a rotatable shaft extending through the valve body and the first seat closure is for translating along the rotatable shaft. A second seat is located in the valve body chamber and a second seat closure is located on a second face of the shuttle. A spring is located substantially between the shuttle spring end and a valve body support. The valve is operable to pass a flow entering the through hole at the shuttle spring end and to spill a flow that closes the first seat closure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described with reference to the accompanying figures. These figures, incorporated herein and forming part of the specification, illustrate the invention and, together with the description, further serve to explain its principles enabling a person skilled in the relevant art to make and use the invention.
FIG. 1 is a schematic diagram of a valve in a flow management system in accordance with the present invention.
FIG. 2 is a diagram of the flow management system of FIG. 1 .
FIG. 3 is a cross-sectional view of a valve of the flow management system of FIG. 1 .
FIG. 4 is a cross-sectional view of a second valve of the flow management system of FIG. 1 .
FIG. 5 is a cross-sectional view of a seal of the flow management system of FIG. 1 .
FIG. 6 is a schematic diagram of a pump-off controller implemented in a traditional production string 600 .
FIG. 7 is a schematic diagram of a valve of FIG. 1 used to implement a pump-off controller.
FIG. 8 is a flow chart showing a mode of operation of the valve of FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The disclosure provided in the following pages describes examples of some embodiments of the invention. The designs, figures, and description are non-limiting examples of certain embodiments of the invention. For example, other embodiments of the disclosed device may or may not include the features described herein. Moreover, disclosed advantages and benefits may apply to only certain embodiments of the invention and should not be used to limit the disclosed invention.
To the extent parts, components and functions of the described invention exchange fluids, the associated interconnections and couplings may be direct or indirect unless explicitly described as being limited to one or the other. Notably, indirectly connected parts, components and functions may have interposed devices and/or functions known to persons of ordinary skill in the art.
FIG. 1 shows an embodiment of the invention 100 in the form of a schematic diagram. A bypass valve 108 is interconnected with a pump 104 via a pump outlet 106 . The pump includes a pump inlet 102 and the valve includes a valve outlet 110 and a valve spill port 112 . In various embodiments, the inlets, outlets and ports are one or more of a fitting, flange, pipe, or similar fluid conveyance.
FIG. 2 shows a section of a typical downhole production string 200 . The production string includes the bypass valve 108 interposed between the pump 104 and an upper tubing string 204 . In some embodiments, a casing 208 surrounds one or more of the tubing string, valve, and pump. Here, an annulus 206 is formed between the tubing string and the casing. A production flow is indicated by an arrow 102 while a backflow is indicated by an arrow 202 . In various embodiments, the bypass valve serves to isolate backflows from one or more of the valve, portions of the valve, and the pump.
FIG. 3 shows a first bypass valve 300 . A valve body 324 houses components including a valve shuttle 337 and a charge spring 312 . The valve body has a central chamber 323 .
The shuttle 337 includes an upper section 340 adjacent to a lower section 341 . In an embodiment, the central chamber includes a first bore 344 for receiving the lower shuttle section and a second bore 346 for receiving the upper shuttle section. In embodiments where the first and second bore diameters are different, a grease space 332 may be provided between the shuttle 337 and the valve body section 370 (as shown). In other embodiments, the first and second bore diameters are substantially the same and there is no grease space.
Upper and lower seals 314 , 330 are fitted circumferentially to the upper shuttle section and the lower shuttle section 340 , 341 . In an embodiment, the seals have a curved cross-section such as a circular cross-section (as shown). In another embodiment the seals have a rectangular cross-section.
In some embodiments, one or more seals 314 , 330 have a structure 500 similar to that shown in FIG. 5 . Here, a seal body 502 such as a polymeric body has inner and outer lip seals 506 , 504 and substantially envelops a charge O-ring 508 such as a silicon rubber ring.
In various embodiments, the seals 314 , 330 are made from one or more of a rubber, plastic, metal, or another suitable material known to persons of ordinary skill in the art. For example, seal materials include silicone rubber, elastomers, thermoplastic elastomers, and metals that are soft in comparison to the valve body 324 , the selection depending, inter alia, on the valve application. In an embodiment, the seals are made from ultra-high-molecular-weight polyethylene.
The shuttle has a through-hole 356 including an upper through-hole section 342 and a lower through-hole section 352 . Upper and lower through-hole ports 362 , 360 bound a flow path through the shuttle indicated by the through-hole. In an embodiment, the upper through-hole cross-section is smaller than the lower through-hole cross-section.
Located near the lower through-hole section are a first seat closure 354 , a first seat 326 , and a seat retainer 393 . In an embodiment, the first seat is about radially oriented with respect to the valve body centerline 301 .
In an embodiment, the first seat closure 354 is a plug. In various embodiments, the first seat closure is spherically shaped, conically shaped, elliptically shaped, or shaped in another manner known to persons of ordinary skill in the art. And, in an embodiment, the first seat closure is substantially spherically shaped. The closure is movable with respect to the shuttle 337 within a cage 328 . When resting against the first seat 326 , the first closure seals the lower through-hole port 360 . In an embodiment, a stabilizer near an upper end of the cage 351 prevents the closure from blocking the passage comprising the upper and lower through-hole sections 342 , 352 when the closure is near the upper end of the cage 390 .
Located near an upper valve body section 350 is a second seat 318 . In an embodiment, the second seat is about radially oriented with respect to the valve body centerline 301 .
A second seat closure 317 is located at an upper end of the shuttle 337 . In an embodiment, the second seat closure is located on a peripheral, sloped face of the shuttle 319 . In various embodiments, the second seat closure is spherically shaped, conically shaped, elliptically shaped, or shaped in another suitable manner known to persons of ordinary skill in the art. And, in an embodiment, the second seat closure is substantially frustoconically shaped. The closure is movable with the shuttle along a line substantially parallel to a centerline of the valve body 301 .
Located near the upper valve body section 350 is a third seat 368 . In an embodiment, the third seat is about radially oriented with respect to the valve body centerline 301 . About radially arranged and located between the second and third seats 318 , 368 , are one or more spill ports 316 extending between a valve body exterior 372 and the valve body central chamber 323 .
A third seat closure 367 is located at a shuttle 337 upper end. In an embodiment, the third seat closure is located on a peripheral, sloped face of the shuttle 319 . In various embodiments, the third seat closure is spherically shaped, conically shaped, elliptically shaped, or shaped in another manner known to persons of ordinary skill in the art. And, in an embodiment, the second seat closure is substantially frustoconically shaped. The closure is moveable with the shuttle along a line substantially parallel to a centerline of the valve body 301 .
The second and third seat closures 317 , 367 are formed to substantially simultaneously close the second and third seats 318 , 368 . When resting against the second and third seats 318 , 368 , the second closure establishes a flow path between a variable volume valve chamber below the shuttle 362 and an upper valve chamber above the second seat 364 while the third closure blocks flow in the spill port 316 . When moved away from the second seat, the second closure unblocks flow in the spill port.
Tending to bias the shuttle 337 upward is the charge spring 312 . In various embodiments, the charge spring is about radially oriented with respect to the valve body centerline 301 and is seated 384 on an annular fixture supported by the valve body 386 . In various embodiments, an upper end of the spring 382 presses against the shuttle.
In normal operation, forces on the shuttle determine the position of the shuttle.
An equilibrium position of the shuttle 337 in the valve body 324 is determined by the forces acting on the shuttle.
For example, when the pump 104 is lifting fluid through the valve 300 , the spring constant k of the charge spring 312 , the area A 1 , and the area A 2 are selected to cause a net upward force on the shuttle tending to move the shuttle to its uppermost position, sealing the spill ports 316 . At the same time, the rising fluid lifts the first closure away from its seat. These actions establish a flow path through the shuttle. In an embodiment, A 1 is greater than A 2 . And, in an embodiment, A 1 is about three times larger than A 2 .
When fluid lifting stops or falls below a threshold value, the net force on the shuttle tends to move the shuttle away from its uppermost position. At the same time, insufficient rising fluid causes the first closure 354 to come to rest against the first seat 326 . These actions unblock the spill ports 316 and establish a fluid flow path from the upper chamber 364 to the spill port(s) 316 while blocking the flow path through the shuttle. In some embodiments, the threshold value is a flow rate specified by the pump manufacturer as being a recommended or safe pump flow rate.
From the above, it can be seen insufficient fluid flow, no fluid flow, or reverse fluid flow cause the valve 300 and pump 104 to be substantially removed from the fluid circuit and/or isolated from the fluid column above the shuttle 337 . A benefit of this isolation is protection of the valve and pump. One protection afforded is protection from solids (such as sand), normally rising with the fluid but now moving toward the valve and pump, that might otherwise foul or block one or both of these components. Blocking the shuttle flow path and opening the spill ports 316 removes these solids outside the tubing string 204 .
In various embodiments the valve 300 is made from metals or alloys of metals including one or more of steel, iron, brass, aluminum, stainless steel, and suitable valve seat and closure materials known to persons of ordinary skill in the art. And, in various embodiments, one or more parts of the valve are made from non-metals. For example, valve closures and seats may be made from one or more suitable polymers such as PTFE (Polytetrafluoroethylene), POM (Polyoxymethylene) and PEEK (Polyetheretherketone). In an embodiment, the closure 354 is made from materials including PEEK.
FIG. 4 shows a second bypass valve 400 . A valve body 424 houses components including a valve shuttle 437 , a valve closure 483 , and a charge spring 412 . The valve body has a central chamber 423 and a rotatable shaft 482 passes through the central chamber. The shuttle includes an upper section 440 adjacent to a lower section 441 .
Upper and lower seals 414 , 430 are fitted circumferentially to the upper shuttle section and the lower shuttle section 440 , 441 . In one embodiment, the seals have a curved cross-section such as a circular cross-section. In another embodiment, the seals have a rectangular cross-section (as shown).
In some embodiments, one or more seals 414 , 430 have a structure 500 similar to that shown in FIG. 5 . Here, a seal body 502 such as a polymeric body has inner and outer lip seals 506 , 504 and substantially envelops a charge O-ring 508 such as a silicon rubber ring.
And, in various embodiments, the seals 414 , 430 are made from one or more of a rubber, plastic, metal, or another suitable material known to persons of ordinary skill in the art. For example, seal materials include silicone rubber, elastomers, thermoplastic elastomers, and metals that are soft in comparison to the valve body 424 , the selection depending, inter alia, on the valve application. In an embodiment, the seals are made from ultra-high-molecular-weight polyethylene.
The shuttle and valve closure 437 , 483 have through-holes 456 , 457 and the rotatable shaft 482 passes through these through-holes. In various embodiments, no “in/out” tools are required to insert the rotatable shaft through the shuttle and valve closure as their hole dimensions pass shafts with diameters as large as the drift of the tubing through which they pass. A first face of the shuttle in the form of a first seat 468 is for sealing against a face of the valve closure 467 . In an embodiment, the first seat is near an upper end of the shuttle 440 and the valve closure sealing face is near a lower end of the valve closure 488 . In some embodiments, the first valve seat is about radially oriented with respect to the valve body centerline 401 . In various embodiments, the shuttle sealing face is integral with or coupled to the shuttle. And, in various embodiments, the valve closure sealing face is integral with or coupled to the valve closure.
A second face of the shuttle 417 is for sealing against a face of the valve body in the form of a second seat 418 . In an embodiment, the second seat is near an upper section of the valve body 450 and the second face of the shuttle is near an upper end of the shuttle 440 . In some embodiments, the second valve seat is about radially oriented with respect to the valve body centerline 401 . In various embodiments, the shuttle sealing face is integral with or coupled to the shuttle. And, in various embodiments, the second seat is integral with or coupled to the valve body 424 .
About radially arranged and located between upper and mid valve body sections 450 , 470 are one or more spill ports 416 . Each spill port extends between inner and outer walls of the valve body 471 , 472 .
Tending to bias the shuttle 437 upward is the charge spring 412 . In various embodiments, the charge spring is about radially oriented with respect to the valve body centerline 401 and is seated 413 in a slot 496 formed in a valve body center section 470 . In an embodiment, an upper end of the spring 415 presses against the shuttle.
During normal operation of a flow management system using the second bypass valve 400 , the shaft 482 rotates and operates the pump 104 . Forces on the shuttle 437 and valve closure 483 determine their position. When the pump 104 is lifting fluid within the tubing and within a designed flow-rate range 490 , the shuttle is in its uppermost position 494 under the influence of the charging spring 412 and the rising fluid lifts the valve closure free of the shuttle 484 . Notably, in its uppermost position, the shuttle blocks the spill ports 416 when shuttle sealing face 417 seals with the first seat 418 . In some embodiments designed flow-rate ranges are the flow-rates specified by the pump manufacturer as recommended and/or safe pump operating ranges.
When the pump 104 ceases to lift fluid at a sufficient rate, as with back-flow 491 , the valve closure contacts the shuttle 486 and the valve closure sealing face 467 seals with the second seat 468 . Further, if pressure P 11 ,P 22 induced forces cause the shuttle to compress the spring 412 , the shuttle moves downward and the spill port(s) 416 is unblocked allowing fluid in the tubing above the valve to spill outside the valve 400 , for example into the annular space between the tubing and the casing 206 . In various embodiments, pressure P 11 acts on an annular area defined by radii r 1 and r 4 while pressure P 22 acts on an annular area defined by r 1 and r 3 . Here, the annular areas are different such as in a ratio range of about 1.5-2.5 to 1 and in an embodiment in a ratio of about 2.0 to 1. In various embodiments, the spill port(s) is unblocked when the shuttle forces resulting from the pressure above the first seat P 22 and the shuttle mass overcome the force of the charging spring 412 and the force resulting from the pressure below the valve closure P 11 .
When the pump 104 ceases to lift fluid at a sufficient rate, as with back-flow 491 , the valve closure contacts the shuttle 486 and the valve closure sealing face 467 seals with the second seat 468 . Further, if pressure P 11 ,P 22 induced forces cause the shuttle to compress the spring 412 , the shuttle moves downward and the spill port(s) 416 is unblocked allowing fluid in the tubing above the valve to spill outside the valve 400 , for example into the annular space between the tubing and the casing 206 . In various embodiments, pressure P 11 acts on an annular area defined by radii r 1 and r 4 while pressure P 22 acts on an annular area defined by r 1 and r 3 . Here, the annular areas are different such as in a ratio range of about 1.5-2.5 to 1 and in an embodiment in a ratio of about 2.0 to 1. In various embodiments, the spill port(s) is unblocked when the shuttle forces resulting from the pressure above the first seat P 22 and the shuttle mass overcome the force of the charging spring 412 and the force resulting from the pressure below the valve closure P 11 .
From the above, it can be seen insufficient fluid flow, no fluid flow, or reverse fluid flow cause the valve 400 and pump 104 to be removed from the fluid circuit and/or isolated from a fluid column above the shuttle. A benefit of this isolation is protection of the valve and pump. One protection afforded is protection from solids (such as sand), normally rising with the fluid but now moving toward the valve and pump, that might otherwise foul or block one or both of these components. Blocking the flow path around the shuttle and opening the spill port(s) 416 removes these solids outside the tubing string 204 .
In various embodiments the valve 400 is made from metals or alloys of metals including one or more of steel, iron, brass, aluminum, stainless steel, and suitable valve seat and closure materials known to persons of ordinary skill in the art. And, in various embodiments, one or more parts of the valve are made from non-metals. For example, valve closures and seats may be made from one or more suitable polymers such as PTFE (Polytetrafluoroethylene), POM (Polyoxymethylene) and PEEK (Polyetheretherketone). In an embodiment, the closure 483 is made from materials including PEEK.
In various embodiments incorporating one or more of the features described above, the bypass valves of FIGS. 3 and 4 provide fouling/plugging protection to valves and fouling/plugging/burn-out protection to pumps due to contaminants such as sand. For example, below design production flow rates causing abnormal valve/pump operation or damage in traditional production string equipment is avoided in many cases using embodiments of the bypass valves of the present invention.
Notably, embodiments of the bypass valves of FIGS. 3 and 4 can replace or supplement protection systems now associated with some production strings. One such protection system is the “pump-off controller” (“POC”) used to protect pumps from failures due to abnormal operations such as reduced flow conditions and loss of flow conditions.
FIG. 6 shows an illustrative example of a pump off controller installation in a production string 600 . The portion of the production string 612 illustrated includes a pump 602 lifting product from a reservoir 614 to the surface 616 . A pump-off controller 608 receives power from a power source 607 and provides power to the pump 610 in accordance with a control algorithm. For example, a pressure indicating device 604 monitors a pressure near the pump discharge 611 and provides a signal indicative of pressure 606 to the pump-off controller. If the pump-off controller determines the indicated pressure is below a preselected low-pressure set point, the POC stops supplying power to the pump. Conditions causing low pump discharge pressure include insufficient product at the pump inlet 613 (i.e. a “dry suction”), pump fouling, and pump damage. Attempting to run the pump under any of these conditions has the potential to damage or further damage the pump.
FIG. 7 shows a pump-off controller embodiment of the present invention 700 . A production string 701 includes a flow management system with a pump 736 interposed between a reservoir 738 and a valve 734 . Product the pump lifts from the reservoir 729 passes first through the pump and then through a bypass valve 734 . The bypass valve discharges 721 into a tubing space 704 of a tubing string 702 that is surrounded by a casing 712 creating an annulus 714 between the outer casing and the inner tubing.
FIG. 8 shows a mode of bypass valve operation that substitutes for or augments a production string pump-off controller 800 . For example, after a period of normal operation 802 , the pressure differential (P 111 >P 222 ) driving the flow in a production string 721 begins to fall 804 . As explained above, low flow conditions cause the closure 354 , 483 to mate with the shuttle 337 , 437 which blocks flow through the valve along its centerline 301 , 401 . When the forces on the shuttle 337 , 437 are no longer sufficient to maintain the shuttle in a position to block the spill port 316 , 416 , the shuttle moves to unblock the spill port/open the bypass 806 . During bypass operation 808 , flow through the valve is blocked and the spill port(s) is open, product flows from the upper tubing string 723 , enters the upper valve chamber 364 , 464 , and leaves the valve through its spill port(s) 725 . The spill port empties into a space such as an annulus between the tubing and the casing 614 .
Because the annulus 614 is fluidly coupled to the reservoir 738 (e.g. as shown in FIG. 7 ), valve bypass from the spill ports is returned to the reservoir 727 in the replenishment step 810 . In various embodiments, filling the reservoir with the fluid from the valve bypass serves to flood the suction of the pump, lift the closure 354 , 483 , and unblock the flow through the valve along its centerline 301 , 401 where normal flow is re-established in step 812 . Re-establishment of normal flow is followed by a return to normal operation in step 814 .
The pump-off control steps of FIG. 8 result, in various embodiments, in cyclic flows through the pump. The time between these cyclic flows is shorter than would occur with a traditional valve in a traditional production string configuration because such strings are unable to bypass flow to the reservoir.
As persons of ordinary skill in the art will appreciate, many production string pumps rely on the pumped product as pump lubrication and coolant. Therefore, reducing the duration of dry pumping periods reduces pump damage due to operation with insufficient lubricant and coolant. The benefits include one or more of longer pump life, fewer outages, and higher production from tight reservoirs.
The present invention has been disclosed in the form of exemplary embodiments; however, it should not be limited to these embodiments. Rather, the present invention should be limited only by the claims which follow where the terms of the claims are given the meaning a person of ordinary skill in the art would find them to have.
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A valve for use in a flow management system comprising a valve including a body, a shuttle, and a seat closure, a rotatable shaft passing through the body and the seat closure, the rotatable shaft for operating a mechanical pump, and, translation of the seat closure along the rotatable shaft operable to mate the seat closure with a seat of the shuttle.
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[0001] The present application claims the benefit of prior provisional application Ser. No. 61/279,932, filed Oct. 29, 2009.
FIELD OF THE INVENTION
[0002] The invention relates to self-primed fibrous constructs of high strength yarn made of ultra-high molecular weight polyethylene (UHMW-PE) with a lower melting polyethylene coating in self-reinforced composites having UHMW-PE or high-density polyethylene (HDPE) as a matrix and further to crosslinking components of the composite using gas-assisted radiation crosslinking to produce material for use in medical applications, police/military protective equipment and sports equipment.
BACKGROUND OF THE INVENTION
[0003] Most pertinent prior art to the instant invention are U.S. Pat. Nos. 5,824,411 (1998), 5,834,113 (1998) by Shalaby et al., which dealt with composites of UHMW-PE reinforced with UHMW-PE of high strength and modulus fibers. The composites have superior mechanical properties relative to non-filled UHMW-PE, including higher strength, impact strength, increased creep resistance and improved modulus. The composites may be sterilized for biomedical use, using gamma radiation and other techniques. Further, the composites are resistant to the effect of body fluids and have lower creep rates so that they will provide implant life. The composites may be crosslinked by exposure to an acetylene environment. Also, the composites find use in other high strength, high impact applications such as sports equipment.
[0004] Other prior are is contained in a series of patents by Klocecek et al., namely, U.S. Pat. Nos. 5,573,824 (1996); 5,879,607 (1999); 6,935,651 (1999); 6,077,381 (2000); and 6,083,583 (2000), which collectively dealt with the same following disclosure: A protective impact resistant material and method, the material comprising a fabric of thermoplastic polymeric fibers having a strength of at least 0.5 GPa and an elastic modulus of at least 25 GPa and a matrix of polymeric material disposed in the interstices between the fibers, the matrix having an elastic modulus in the rant 0.2 to 3×10 6 psi. The polymeric fibers can be gel spun polyethylene, polypropylene, nylon, polyvinyl alcohol and polyethylene terephthalate. In a second embodiment, the matrix is derived from the fabric. The method of making the material comprises providing a matrix of melted polymeric material transparent to energy of a predetermined type and having a predetermined melting temperature, placing a fabric of polymeric fibers having a melting temperature higher than the melting temperature of the matrix in the matrix, applying a pressure of 1000 to 2000 psi to the fabric disposed in the matrix, then raising the temperature to the melting temperature of the fabric for the minimum time required to cause consolidation of the fabric and the matrix and rapidly cooling the consolidated fabric and matrix to a temperature below the melting temperature of the fabric. In accordance with a second embodiment here is provided a fabric of polymeric fibers as in the first embodiment which is operated upon as in the first embodiment to cause melting of a sufficient portion of the fabric to fill the interstices between the fibers of the fabric and the fabric is then rapidly cooled to a temperature below the melting temperature of the fabric.
[0005] However, the prior art was silent on means to maximize the effectiveness of self-reinforcement using high strength UHMW-PE fibers in a chemically identical HDPE or UHMW-PE matrix. This provided an incentive to pursue the study, subject of this invention. Accordingly, this invention deals with the use of a relatively low melting polyethylene primer to provide a low melting interface between the high strength reinforcing UHMW-PE fiber and the continuous phase of the matrix PE or UHMW-PE without compromising the orientation and hence, the strength and modulus of the UHMW-PE fibers.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a self-primed fabric in a self-reinforced polyethylene composite with a fabric/matrix weight ratio of 13/87 to 43/57, the self-primed fabric comprising ultra-high molecular weight polyethylene fibers, wherein the self-primed fabric is made by the method of dipping the fabric in less than 20 percent solution of low-or high-density polyethylene in xylene at temperatures of 105° C. to 120° C., the fabric is withdrawn from the solution, dried in an air circulating hood and weighed for percent add-on, and wherein the matrix is made of ultra-high molecular weight polyethylene and the fabric is self-primed with less than 20 weight percent of low-or high density polyethylene, and further wherein the fabric is a warp-knitted mesh. Additionally, such self-primed fabric in the self-reinforced polyethylene composite irradiated with about 25 to 60 kGy of high energy radiation in the presence of at least one reactive gas selected from the group consisting of acetylene, butadiene, chlorotrifluoroethylene and vinylidine fluoride.
[0007] Another aspect of this invention deals with a self-primed fabric in a self-reinforced polyethylene composite with a fabric/matrix weight ratio of 13/87 to 43/57, the self-primed fabric comprising ultra-high molecular weight polyethylene fibers, wherein the matrix and the fabric are made of high-density polyethylene and gel-spun, ultra-high molecular weight polyethylene fiber, respectively, the fabric is self-primed with less than 20 weight percent of low density polyethylene, wherein said composite is irradiated with less than 60 kGy of high energy radiation in the presence of at least one reactive gas selected from the group consisting of acetylene, butadiene, chlorotrifluoroethylene and vinylidine fluoride. For certain applications, the said composite is irradiated with 30 kGy of high energy radiation in the presence of acetylene gas to produce crosslinked articles for use in one or more application selected from those associated with orthopedic and maxillofacial surgeries, protection against impinging bullets, surfboard components, helmets, shipping containers, and impact resistant sports equipment.
[0008] From an application perspective, this invention deals with a self-primed fabric in a self-reinforced polyethylene composite with a fabric/matrix weight ratio of 13/87 to 43/57, the self-primed fabric comprising ultra-high molecular weight polyethylene fibers, wherein the matrix and the fabric are made of high-density polyethylene and gel-spun, ultra-high molecular weight polyethylene fiber, respectively, the fabric is self-primed with less than 20 weight percent of low density polyethylene, wherein said composite is irradiated with 25 to 40 kGy of high energy radiation in the presence of acetylene gas to produce crosslinked materials in at least one form selected from the group consisting of bullet-proof vests, high impact components of car seats, helmets, impact resistant sports equipment, explosion resistant shipping containers and surfboard components.
[0009] A significant aspect of the invention deals with a self-primed fabric in a self-reinforced polyethylene composite with a fabric/matrix weight ratio of 13/87 to 43/57, the self-primed fabric comprising ultra-high molecular weight polyethylene fibers, wherein the self-primed fabric is made by the method of dipping the fabric in less than 20 percent solution of low-or high-density polyethylene in xylene at temperatures of 105° C. to 120° C., the fabric is withdrawn from the solution, dried in an air circulating hood and weighed for percent add-on and wherein the priming solution contains at least one additive selected from the group consisting of antimicrobial agents, anti-inflammatory agents, organic dyes and cell growth promoters.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] In one aspect the present invention is directed to a significant improvement over the prior art on the preparation of fiber self-reinforced UHMW-PE wherein both the fibers and matrix are made of UHMW-PE with up to 12 weight percent of the fiber reinforcement and an intimate interface between the fibers and matrix to maximize the effectiveness of the reinforcement. Specifically, the improvement over the prior art as described in the instant invention entails the use of a thin layer of low-melting, high-density and/or low-density polyethylene to abridge the UHMW-PE fibers and matrix, thus allowing the use of more than 12 weight percent of the reinforcing fiber leading to significant increase in the maximum strength, creep resistance, toughness, and other related properties. The low-melting abridging component of the instant invention is, in effect, a primer applied from a hot solution of a low-melting polyethylene from its solution in a solvent (e.g., xylene) that wets and can dissolve the uppermost surface layer of the UHMW-PE fibers. Drying the primed, or better denoted the self-primed, fibers that constitute a warp-knitted mesh yields a self-primed fabric which can be easily incorporated into a self-reinforced composite of UHMW-PE (or HDPE) matrix with the self-primed fabric or mesh. Constructing or assembling the later in such a manner (1) provides a facile method for assembly of the composite; (2) allows the use of minimum temperature by virtue of the low-melting primer, intimately abridging the UHMW-PE (or HDPE) matrix with the UHMW-PE fibers (e.g., in the form of a mesh) without compromising the high degree of fiber orientation, and hence retaining the strength of the reinforcing phase—additionally, the application of a low-melting primer, which can be applied from a solution at 105 to 120° C. permits the use of additives, including temperature sensitive additives, which can impart desirable properties to the composites and this entails the use of (a) organic dyes to color or tint the composite; (b) antimicrobial agents to provide a long-term sustained release of these agents and hence, prolonged antimicrobial activity; and (c) certain other agents including antioxidants, anti-inflammatory drugs and cell growth promoters; (3) makes it possible to stack several layers of the preformed UHMW-PE (or HDPE) sheets and self-primed reinforcing meshes in more than one pattern, thus yielding composites with variable thickness and degrees of anisotropy between the two major surfaces of the composites—this, in part, provides a high degree of freedom in designing the composite for use in medical and non-medical products with variable load-bearing and mechanical property requirements across the surface and thickness of the different composite devices; and (4) allows the incorporation of more than 12 weight percent of the mesh in the composite and hence maximizing the properties of the reinforced construct.
[0011] Further illustrations of the present invention are provided by the following examples:
EXAMPLE 1
Preparation of a Typical Warp-knitted Mesh
[0012] For mesh preparation, a multifilament, 650 denier yarn made of UHMW-PE comprising 120 filaments was used. The single filament diameter was 30 μm. The yarn exhibited a tensile strength of 2 GPa. The yarn was twisted to yield one twist per inch prior to warping and knitting, using a GE 203A warper and TR-6-E18 Rachel 6-bar knitting machine, respectively. The resulting warp-knitted mesh has 21 courses per inch and fabric width of 117.2 mm. The knitted fabric was cut into 12, five-inch pieces. To remove any fiber finishing additives, the meshes were sonicated in isopropyl alcohol for 5 minutes and dried prior to self-priming.
EXAMPLE 2
Preparation of Self-primed Knitted Fabric using Mesh from Example 1
[0013] For self-priming, a typical warp-knitted mesh from Example 1 was dip-coated in a 6 percent solution of low density polyethylene in xylene at 110° C. for about 15 seconds. The mesh was removed and allowed to dry in a laminar flow hood until a constant weight was realized
EXAMPLE 3
Preparation of a Typical UHMW-PE Sheet
[0014] To prepare the UHMW-PE sheet components for use in assembling the self-reinforced composites, the polymer powder was compression-molded in a Carver Laboratory Press using a stainless steel mold. Using a temperature of 180° C. and pressure of 30,000 lbs. for 30 minutes allowed the conversion of the UHMW-PE powder into uniform sheets having a thickness of 1.3 mm.
EXAMPLE 4
Preparation of Typical Self-reinforced Composite with Variable Fractions and Locations of the Self-primed Mesh in the Matrix
[0015] The first step toward assembling a self-primed mesh from Example 2 into a fiber self-reinforced mesh entails stacking the UHMW-PE sheets from Example 3 and the self-primed meshes from Example 1 in two patterns, I to IV. In Pattern I, three sheets were stacked in an alternating manner with two meshes and three sheets. In Pattern II, two meshes were stacked in an alternating manner with three sheets topped with two additional sheets. And a Carver Laboratory Press and a special mold to keep the mesh under tension (or strained) were used to form self-reinforced composite sheets having variable thickness according to the following scheme:
[0016] Step 1: Stacked components were heated at 140° C. under 15,000 lbs. pressure for 30 minutes.
[0017] Step 2: The pressure on the heated stacks was increased to 30,000 lbs. and the temperature was maintained at 140° C. for 60 minutes.
[0018] Step 3: The stacked components were allowed to cool to 110° C. and annealed under 30,000 lbs. of pressure for 60 minutes.
[0019] The preparation and properties of the composites based on typical primed meshes using Patterns I and II are summarized in Table I.
[0000]
TABLE I
Comparative Properties of Typical N-I and N-II Patterns,
UHMW-PE Composites Using Unprimed and Self-primed Meshes a
Mesh
Mechanical Properties b
Com-
Orien-
Thick-
Max.
posite
tation c
Self-
ness
Strength
Modulus
No.
(Degree)
Pattern
Priming
mm
MPa
MPa
U-P
0-0
I
No
3.7
37
652
P-1
0-0
I
Yes d
3.9
50
718
P-2
0-0
II
Yes d
4.5
54
651
a The mesh was strained during composite assembling and compression molding.
b Using the 3-point bend method.
c Zero (0) indicates the wale direction of the mesh.
d Percent add-on of primer was about 9% based on mesh weight.
EXAMPLE 5
Preparation of Typical Self-reinforced Composite with Unprimed Mesh
[0020] A self-reinforced mesh based on unprimed mesh from Example 1 and a UHMW-PE sheet from Example 3 were prepared following the same procedure used in Examples 4-6 for the self-primed meshes having stacking Pattern I. Preparation and properties of composites based on typical unprimed meshes using Pattern I are summarized in Table I.
EXAMPLE 6
Preparation of Typical Self-reinforced Composites of Self-primed Mesh without Straining the Mesh
[0021] Two stacking patterns, III and IV, were used to prepare the composites without straining the meshes. In Pattern III, the compositions were stacked as follows: 3 sheets+mesh+sheet+mesh+sheet. In Pattern IV, the components were stacked as follows: 3 sheets+mesh+2 sheets+mesh+sheet. The molding scheme entailed the use of preformed plates and a two-stage cycle: First Stage, 145° C., 15,000 lbs. for 30 minutes; Second Stage: 110° C., 15,000 lbs. for 30 minutes. Preparation and properties of the compositions are summarized in Table II.
[0000]
TABLE II
Comparative Properties of Typical N-III and N-IV Pattern
UHMW-PE Composites Using Self-primed Meshes a
Mesh
Mechanical Properties b
Com-
Orien-
Thick-
Max.
posite
tation c
Self-
ness
Strength
Modulus
No.
(Degree)
Pattern
Priming
mm
MPa
MPa
P-3
0-0
III
Yes d
5.8
82
446
P-4
0-0
IV
Yes d
6.8
60
309
a Meshes were not strained during composite assembling and compression molding.
b Using a 3-point bend method.
c Zero (0) indicates the wale direction of the mesh.
d Percent add-on of the primer was about 9% based on mesh weight.
EXAMPLE 7
A Typical Gas-assisted Crosslinking of Meshes from Examples 4-6
[0022] To maximize crosslinking of the chains of all components of the composite and to allow for some bridging between the primed mesh and sheet, the self-reinforced polyethylene composites of Examples 4 to 6 were irradiated with 30 kGy of gamma radiation in the presence of an acetylene gas. The effects of the gas-assisted bridging of the different components of the composites and the chain crosslinking the individual components were assessed in terms of (1) extent of swelling in xylene at 110° C., and (2) effect on modulus and breaking strength.
[0023] Although the present invention has been described in connection with the preferred embodiments, it is to be understood that modifications and variations may be utilized without departing from the principles and scope of the invention, as those skilled in the art will readily understand. Accordingly, such modifications may be practiced within the scope of the following claims. Moreover, Applicant hereby discloses all subranges of all ranges disclosed herein. These subranges are also useful in carrying out the present invention.
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A self-reinforced polyethylene composite includes a self-primed fabric reinforcement, such as a warp-knitted mesh, and has a fabric/matrix weight ratio of 10/90 to 45/55. Prior to inclusion in the composite the fabric reinforcement is self-primed by dipping in a polyethylene priming solution. The composite is derived from pre-formed sheets stacked in different patterns which yield upon compression molding into composite devices with variable thickness and degrees of mechanical properties. The primer may contain one or more additives to impart certain properties to the final composite.
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BACKGROUND OF THE INVENTION
This invention relates to the treatment and sterilization of liquids by means of ultraviolet radiation. More particularly, the invention provides a novel apparatus for irradiating drinking water to kill microorganisms commonly found in water supplies which cause sickness in human beings.
Contaminated water is a major cause of sicknesses that often plague travelers to foreign countries. Microorganisms in the water supply are also a concern for backpackers, hikes, and campers who are away from drinking water supplied by modern water treatment facilities. The microorganism which is the major cause of stomach disorders in travelers is coliform bacteria.
It is known that ultraviolet radiation can be used to kill organic contamination within water supplies. U.S. Pat. No. 1,473,095 to Henri et al discloses an apparatus for sterilizing liquids by means of ultraviolet rays. In the patent water is passed through quartz tubes in proximity to an ultraviolet source to sterilize the water by making it free of living microorganisms. Other apparatus have been developed for the sterilization of drinking glasses such as U.S. Pat. No. 1,961,700 to Moehler; and for sterilization of medical or dental equipment such as found in U.S. Pat. No. 4,448,750 to Fuesting.
In spite of the general knowledge of UV sterilization of drinking water, the technique heretonow has been applied mainly in dedicated water supply systems for community use or in laboratory settings. The need for a UV source which can be safely employed in a portable personalized water sterilizer has remained unsatisfied.
SUMMARY OF THE INVENTION
The present invention is a portable UV water sterilizer which can be taken anywhere by travelers to provide a means of eradicating harmful microorganisms in drinking water. The unit is small, holding in the range of 10-30 ozs. of water in a lid containing an ultraviolet lamp powered by batteries. Activation of the ultraviolet source produces radiation with a wavelength of approximately 254 nanometers. The shape of the reservoior allows the ultraviolet radiation to penetrate throughout the reservoir sterilizing virtually all living microorganisms in just a few minutes. The sterilizing apparatus is adaptable for use with timers and signal lights to indicate the completion of the sterilization cycle. Additionally, the shape of the reservoir permits the emptying of the sterilized liquid from the container while leaving sediments behind.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of one preferred embodiment of the PORTABLE UV WATER STERILIZER is hereafter described with specific reference being made to the drawings in which:
FIG. 1 is a perspective view of the present invention; and
FIG. 2 is a cross-sectional view of the top housing of the apparatus shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, FIG. 1 shows a bottom housing 10 forming a reservoir 12 for the containment of a liquid. The bottom housing 10 is on the order of 41/2 inches (11.4 cm) high by 61/2 inches (16.5 cm) long by 2 inches (5 cm) wide. The size permits the reservoir to hold approximately 20 ozs. (600 ml) of water. The bottom housing 10 can be made of plastic or other material and has radiused outer edges to provide ease of grasping and handling.
Adapted to mate with the bottom housing is the top housing or lid 20 which contains the ultraviolet source and the control unit and associated power supply. Shown in FIG. 1 is the on/off switch 22, indicator light 24 and safety inter-lock 26.
FIG. 2 is a cross-sectional view of the top housing or lid as shown in FIG. 1. In the preferred embodiment being disclosed, power to the ultraviolet bulb is provided by 4 AA batteries, two of which are shown in the figure as numeral 30. On/off switch 22, shown in FIG. 1, activates circuit board 40. Contained on circuit board 40 are various resistors, capacitors, a transistor and a transformer. When activated the electronic circuit creates a voltage sufficient to ignite UV lamp 50 and subsequently sustain its operation.
The circuitry contained within the top housing 20 is generally known in the art and is the type used to energize fluorescent lamps. The one employed in the present invention is that of Transistorized Super-Mini Fluorescent Flashlight manufactured by JML Model No. 1195 having a UK Registration Design No. 983,626. Various equivalents by different manufacturers are readily available.
Lamp 50 as shown in FIG. 2 is a custom mercury ultraviolet lamp from UVP, Inc. P.O. Box 1501 San Gabriel, Calif. 91778. The lamp is a 6" atmospheric pressure ultraviolet lamp having a quartz envelope. Lamp 50 fits in lamp holder 32 and is electrically connected to circuit board 40. During operation, the lamp has an output of approximately 4 watts and a wavelength spectral output peak of 254 nanometers. Alternatively, various ultraviolet germicidal lamps may be employed from various manufacturers including General Electric Corporation of Schenectady, N.Y. As seen from FIG. 2, lamp 50, batteries 30 and circuit board 40 are recessed within top housing 20 to position these components entirely above bottom housing 10 when housings 10 and 20 are engaged.
To aid in the rapid sterilization of the liquid contained in the reservoir, a reflector 28 may be employed in the top housing to direct the ultraviolet radiation from the back side of the bulb towards the reservoir.
For best operation and efficient distribution of the ultraviolet rays, the walls 14 of the reservoir opening 12 are coated with a material which reflects ultraviolet radiation. Alternatively, a separate container shown in FIG. 1 as numeral 16 can be inserted into the reservoir opening 12 and contiguous with walls 14. If the reservoir insert 16 is made of a reflective material such as smooth aluminum or stainless steel, the walls of the insert will reflect the ultraviolet rays and provide an even and efficient distribution of the ultraviolet radiation. The use of insert 16 provides a lightweight container for filling with water to be sterilized and allows the water to be poured out leaving the sediments behind.
Since direct exposure to ultraviolet radiation can be harmful to the operator, a safety inter-lock switch 26 is applied to deactivate the ultraviolet lamp if the top housing 20 is removed from the lower housing 10.
Top housing 20 is designed to mate with the lower housing to provide a light-tight seal between the top and bottom housings to prevent escape of ultraviolet radiation. The top housing may be hinged, snap-on, or frictionally fit upon the bottom housing 10.
Testing of a prototype unit showed that the total coliform bacteria count from a sample of lake water having an initial coliform bacteria content too numerous to count, was reduced to a coliform bacteria count of 1 per 50 milliliters, after being subjected to ultraviolet radiation within the prototype unit for one minute. After three minutes of ultraviolet radiation, the total coliform bacteria was less than 1 per 50 milliliters.
A control unit for the portable UV water sterilizer may contain a timer circuit which shuts off the unit upon the elapse of a predetermined time of ultraviolet exposure. Alternately, a dosage meter could be incorporated into the control unit to end the ultraviolet radiation after the accumulation of a predetermined dosage. As shown in FIG. 1, indicator light 24 is used to indicate when the lamp is lit. The indicator lamp may be a seprate bulb, an LED, or an optical fiber leading from the UV lamp itself.
It will, of course, be understood that various changes may be made in the form, details, arrangement and proportions of the parts without departing from the scope of the invention which consists of the matter shown and described herein and set forth in the appended claims.
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A portable container providing a means for the sterilization of drinking water by ultraviolet radiation. The container has a bottom housing serving as a reservoir for holding the water and a mating top housing containing the ultraviolet source. Powered by batteries the ultraviolet source provides efficient sterilization throughout the reservoir, the reservoir preferably having ultraviolet reflecting sidewalls.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/778,426, filed on Feb. 27, 2013, now issued as U.S. Pat. No. 9,061,109, which is a continuation of U.S. application Ser. No. 12/804,506, filed on Jul. 22, 2010, now issued as U.S. Pat. No. 8,463,364, which claims priority on U.S. Provisional Application Ser. No. 61/271,587, filed on Jul. 22, 2009, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Drawing blood and administering intravenous medication using medical devices including but not limited to catheters are common medical procedures, but conventional methods to perform these procedures have several limitations. First a vein must be found. Conventional methods of locating an appropriate vein or artery include restricting the blood supply to the location of the body so that the blood pressure in that area is greater, which results in the patient's veins becoming more visible. This is often accomplished by the use of a temporary tourniquet, which can result in extreme discomfort to the patient. Even after the temporary tourniquet is applied and certain veins are exposed, a medical professional may still not be able to find an appropriate vein. This problem can occur more readily in elderly patients and patients with low blood pressure. Thus, there is a need for a non-invasive method for locating veins.
SUMMARY OF THE INVENTION
The present invention is directed towards a portable hand-held medical apparatus that uses infrared light to detect veins beneath the skin, then illuminating the position of the veins on the skin surface directly above the veins using visible light. When the apparatus is held a distance above the outer surface of the skin, veins appear vastly different than the surrounding tissue, and veins that are otherwise undetectable because of their depth in the tissue are safely located and mapped on the patient's skin. Vein's will be accessed more readily and with greater confidence and as such, venipuctures will go more smoothly while vasculature shows up clearly on the skin's surface, making it easy to select the best vein to collect a blood sample from or administer medications to. Qualified medical personnel can observe the displayed vasculature to assist them in finding a vein of the right size and position for venipuncture.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus of the present invention.
FIG. 2 is a perspective view of a charging cradle for the apparatus of FIG. 1 .
FIG. 3 is a front view of the apparatus of FIG. 1 , while being charged in the cradle of FIG. 2 .
FIG. 4 is a perspective view of the apparatus of FIG. 1 being charged in the cradle of FIG. 2 .
FIG. 5 is a side perspective view of the apparatus of FIG. 1 , highlighting the buttons and LCD screen of the device of FIG. 1 .
FIG. 6 is a bottom view of the apparatus of FIG. 1 .
FIG. 7 is an image of a health care professional utilizing the apparatus of FIG. 1 to enhance the vein image of veins in a patient's arm.
FIG. 8 is a Figure illustrating proper angling of the apparatus when being used to enhance the vein image of veins in a patient's arm.
FIG. 9 is a Figure illustrating proper centering of the apparatus when being used to enhance the vein image of veins in a patient's arm.
FIG. 10 is a perspective view of the apparatus of FIG. 1 , with the battery cover removed to show the battery compartment.
FIG. 11 is a perspective view of the apparatus showing removal of the battery cover.
FIG. 12 is a perspective view of the apparatus with the battery cover removed, exposing the battery when properly installed in the battery compartment.
FIG. 13 is a perspective view of battery of the apparatus.
FIG. 14 is a series of images identifying different indications the LCD display will provide for different battery power levels.
FIG. 14A illustrates a Low Battery message displayed on the LCD of the device.
FIG. 15 is a screen shot of the LCD start screen.
FIG. 15A is a screen shot of the LCD when utilized for making configuration setting changes.
FIG. 15B shows all of the LCD button icons and their functionality.
FIG. 16 is a series of screen shots of the LCD display used for modifying the default Vein Display Setting.
FIG. 17 is a series of screen shots of the LCD display illustrating changing of the Display Time-out interval.
FIG. 18 is a screen shot illustrating how to change the Backlight Intensity of the apparatus.
FIG. 19 is a screen shot of the LCD screen used for changing the speaker volume of the apparatus.
FIG. 20 is a series of screen shots showing the steps for labeling of the apparatus according to a user's preference.
FIG. 20A is a series of screen shots showing use of up/down arrows for character selection.
FIG. 21 is a screen shot illustrating how to change or review the language utilized on the apparatus.
FIG. 22 is a screen shot illustrating how to reset all of the settings for the apparatus back to the factory default settings.
FIG. 23 is a perspective view illustrating plugging a USB cable into the back of the apparatus to communicate with a PC, and a screen shot illustrating the LCD screen of the device schematically illustrating the connection.
FIG. 24 is a screen shot as it would appear on the PC of FIG. 23 when looking for the apparatus.
FIG. 25 is a screen shot as it would appear on the PC after the apparatus was detected, and the software running on the PC was checking to see if the apparatus software was current or needed to be updated.
FIG. 26 is a screen shot as it would appear on the PC, when an apparatus is not detected by the PC.
FIG. 27 is a screen shot illustrating the capability of naming the apparatus or changing the language, and doing so from the PC.
FIG. 28 is a series of screen shots of the PC illustrating the steps in which the software of an apparatus is updated.
FIG. 29 illustrates a cradle pack and mounting hardware for use in a medical environment utilizing a series of vein enhancing apparatuses.
FIG. 30 is an exploded view of the apparatus of the present invention.
FIG. 31 shows a bottom perspective view of the bottom section of the housing.
FIG. 32 shows a top perspective view of the bottom section of the housing.
FIG. 33 is a top view of the bottom section of the housing.
FIG. 34 is a cross-sectional view of the bottom section of the housing.
FIG. 35 is a bottom view of the bottom section of the housing.
FIG. 36 is an end view of the bottom section of the housing.
FIG. 37 is a top view of the top section of the housing.
FIG. 38 is a side view of the top section of the housing.
FIG. 39 is a bottom view of the top section of the housing.
FIG. 39A is a cross sectional view through the apparatus of FIG. 39 .
FIG. 40 is a first section cut through the top section of the housing.
FIG. 41 is a second cross-section through the bottom section of the housing.
FIG. 42 is an exploded view of the photodiode assembly.
FIG. 42A is a reverse perspective view of the photodiode board in the exploded view of FIG. 42 .
FIG. 43 is a top view of the photodiode assembly.
FIG. 44 is an bottom view of the photodiode engine.
FIG. 45 shows a perspective view of the bottom section of the housing with a portion of the photodiode assembly mounted inside the cavity of the bottom section of the housing.
FIG. 46 is a bottom view of the portable apparatus of the present invention.
FIG. 47 is a view of the inside of the battery cover.
FIG. 47A is a view of the outside of the battery cover.
FIGS. 48A-D is a assembly level block/schematic diagram of the present invention
FIGS. 49A-C is an additional assembly level block diagram of the present invention.
FIGS. 50A-D is a schematic of a circuit diagram of the user interface board.
FIGS. 51A-B is a schematic of a circuit diagram of the photodiode board connection.
FIG. 52 is a schematic of a circuit diagram of the USB chip.
FIGS. 53A-E is a schematic of a circuit diagram of the photodiode board.
FIG. 54 is a schematic of a circuit diagram of the battery connector board.
FIGS. 55A-E is a schematic of a circuit diagram of the visible laser drive.
FIGS. 56A-D is a schematic of a circuit diagram of the laser safety feature of the present invention
FIGS. 57A-D is an additional schematic of a circuit diagram of the photodiode engine.
FIGS. 58A-E is a schematic of a circuit diagram of the speaker of the present invention.
FIGS. 59A-G is an additional schematic of a circuit diagram of the photodiode engine.
FIGS. 60A-F is an additional schematic of a circuit diagram of the photodiode assembly.
FIGS. 61A-E is a schematic of a circuit diagram of a microcontroller of the present invention.
FIGS. 62A-D is a schematic of a circuit diagram of the power supply of the present invention.
FIGS. 63A-B is an additional schematic of a circuit diagram of the power supply and its peripheral connections.
FIGS. 64A-E is a schematic of a circuit diagram of the battery management system.
FIGS. 65A-D a schematic of a circuit diagram of the photodiode engine.
FIGS. 66A-E illustrates the graphical or symbolic information that may be projected onto a patient other than just vein imaging.
FIG. 67A illustrates a first arrangement of optical detectors that may be used for the apparatus.
FIG. 67B schematically illustrates an alternative arrangement of optical detectors.
FIG. 67C illustrates a second alternative arrangement for the optical detectors.
FIG. 68 illustrates one mechanical arrangement for the scanning mirrors.
FIG. 69 illustrates smoothing of the edges of the scanning mirrors to improve the high resolution images at smooth video rates.
FIG. 70 illustrates the apparatus illuminating on the skin of a patient, a coated needle that has been inserted beneath the patient's skin.
FIG. 71A illustrates a typical return signal collected from photodiodes of the current invention, with local peaks corresponding to vein locations.
FIG. 71B represents the same signal of FIG. 71A after differentiation.
FIG. 72 illustrates a few consecutive scan lines crossing a single vein.
FIG. 73 is a graph showing the output power versus the forward current for a laser, to illustrate an inflection point.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to an apparatus 10 ( FIG. 1 ) that is an opto-electronic device that assists medical practitioners by locating veins and then projecting an image of those veins directly on a patient's skin. The apparatus may be portable, hand held, and battery powered. However in an alternative embodiment an external power supply may be used to power the apparatus. The apparatus operates by using infrared light to detect veins beneath the skin, and then illuminates the position of the veins on the skin surface directly above the veins using visible light. The apparatus 10 may be battery powered, and rechargeable using a cradle 5 ( FIG. 2 ), and may generally be stored therein ( FIGS. 3-4 ).
The apparatus 10 generally comprises a housing 11 , internal circuitry 12 , keypad 13 , display 14 , scanner assembly 15 , and battery pack 16 . The housing 11 may generally comprise a top section 17 and bottom section 18 as shown in FIG. 30 . Although a specific shape for the housing and the top and bottom sections are shown it will be appreciated that this is merely a representative example and other configurations are intended to be included in the invention. The function of the housing 11 is to for example provide a location to mount the internal circuitry 12 , keypad 13 , display 14 , scanner assembly 15 , and battery 16 . A general embodiment of the housing will be disclosed, but it will be generally understood that modifications to the housing to accommodate different internal circuitry, keypad, display, laser assembly, and battery are within the scope of this invention. In addition, if other features are desired the housing may be modified to include those features.
The housing 11 may be comprised generally of a top section 17 and a bottom section 18 . FIGS. 31 and 32 show a representation of one embodiment of the bottom housing section 18 of the housing 11 , in perspective views, and which are detailed in FIGS. 33-36 . As seen in FIGS. 31 and 32 , the bottom housing section 18 generally comprises a left sidewall 19 and a right sidewall 20 , which are connected by a front wall 22 and rear wall 23 . The exterior surfaces of those walls, which may be handled by the user, are seen in FIG. 35 , while the interior surfaces of those walls, which may receive the electronic circuitry and other components, are visible in FIG. 33 .
The walls 19 - 22 may each be angled, and may be so angled simply for aesthetic reasons, or for better handling by a user, or the angling (draft) may be the result of the manufacturing process used to create the housing bottom section 18 , possibly being a casting process, a forging process, or a plastic injection molding process. However, the walls 19 - 22 need not be so angled, and the housing bottom section 18 may also be manufactured using any other suitable manufacturing process or processes, including, but not limited to, machining of the part. One end of the angled walls 19 - 22 may terminate in a generally flat bottom wall 23 , to create an internal cavity 24 . The generally flat bottom wall 23 may transition, using transition wall 25 , into another generally flat wall 23 A. Wall 23 A may be interrupted by a series of internal walls ( 26 A, 26 B, 26 C, and 26 D) extending therefrom and an internal top wall 26 E connecting those internal side walls, to form a compartment that may house the battery 16 . The other end of the angled walls 19 - 22 may terminate in an edge 27 . Edge 27 , at front wall 21 and in the nearby regions of sidewalls 19 and 20 , may be generally planar, but may transition into edge 27 A, which serves as a transition to generally planar edge 27 B that begins at rear wall 22 . Each of the edges 27 , 27 A, and 27 B of the housing bottom section 18 may have a step for receiving a corresponding protruding flange of the housing top section 17 , when they are joined during assembly of the apparatus 10 .
In one embodiment, the front wall 21 and sidewalls 19 and 20 of the housing bottom section 18 may have extending up towards the plane of the edge 27 , one or more cylindrical members—a boss 107 , which is adapted to receive mounting screws 106 , and may include the use of threaded inserts for mounting of the housing top section 17 to the housing bottom section 18 . It will be appreciated that other mounting means may be used, including, but not limited to, the use of a snap closure, or a post and recess combination with a friction fit therebetween.
The bottom wall 23 of housing bottom section 18 may be provided with two orifices 28 , and 29 . On the outside surface of bottom wall 23 there may be one or more annular recesses 28 A and 29 A, being concentric to orifices 28 and 29 , respectfully, each of which may be used to receive a lens 90 ( FIGS. 6 and 10 ).
Protruding inward from the inside of bottom wall 23 may be cylindrical protrusions 31 , and 32 . Protrusions 31 and 32 may be concentric with orifices 28 and 29 , respectfully, and may be adapted to receive a portion of the photodiode masks 66 and 67 of the scanner assembly 15 , which are discussed later.
Mounted inside the battery compartment formed by walls 26 A- 26 E may be the battery pack 16 . The battery pack 16 ( FIG. 13 ) can be any of a variety of models known in the art, but in a preferred embodiment, it may be rectangular to fit inside the compartment formed by walls 26 A- 26 E. One end 16 A of the battery pack 16 may be adapted to be received by the power connection 95 on the main circuit board ( FIG. 30 ). The battery pack 16 may be secured in the battery compartment by a battery cover 96 which attaches to the bottom section 18 of housing 11 . The battery cover 96 may attach to the bottom section of the housing 18 in a variety of ways, such as by clips or screws. As seen in FIG. 47 , the battery cover 96 may be secured by having a pair of flanges 96 A extending therefrom be received in a pair of slots 34 in the bottom section 18 of housing 11 . FIGS. 62-64 are schematics of circuit diagrams which demonstrate how the battery pack is connected to the internal circuitry 12 , the scanner assembly 15 , and remaining electrical components of the invention.
FIGS. 37-41 show a representation of one embodiment of the top section 17 of the housing. 11 . The housing top section 17 may be formed similar to the housing bottom section 18 , and thus may have a top wall 81 from which extends, generally at an angle, a left sidewall 83 and right sidewall 84 , and a front wall 85 and rear wall 86 . The front wall 85 and rear wall 86 may extend from the left sidewall 83 and right sidewall 84 , respectively, creating an internal cavity 87 . FIG. 37 shows the outer surfaces of those walls, while FIG. 39 shows the inner surfaces of those walls. The walls 83 - 86 extend out to a generally planar edge 82 , which may have a peripheral flange protruding therefrom to mate with the recess of the housing bottom section 18 . In one embodiment, housing top section 17 may have extending down from top wall 81 and walls 83 - 86 , towards the plane of the edge 82 , one or more cylindrical members 108 , which are adapted to receive mounting screws 106 , and may include use of threaded inserts. The cylindrical members 108 of the housing top section 17 may be positioned to be in line with the corresponding members 107 of the housing bottom section 18 to be secured thereto during assembly of the scanner 10 .
The outer surface of the top wall 81 of the housing top section 17 may have a step down into a flat recessed region 81 A having an edge periphery 81 P. That flat recessed region 81 A may comprise of an opening 91 through to the inside surface, which may be a rectangular opening, and a plurality of shaped orifices 93 A, 93 B, and 93 C. The rectangular-shaped opening 91 may be sized and otherwise adapted to receive the display 14 , which is discussed in more detail hereinafter. The flat recessed region 81 A of top wall 81 may receive a display guard 92 ( FIG. 30 ), to provide a barrier between the display 14 and the outside environment. The plurality of shaped orifices 93 , which may also be correspondingly found in the display guard 92 , are adapted to receive a plurality of buttons 77 or other activating means which may be mounted directly under the top plate 81 of the housing top section 17 . In a preferred embodiment, there are three buttons—a first display button 110 , a second display button 111 , and a power button 112 . Buttons 110 - 112 may be any shape practicable, but in a preferred embodiment, display buttons 110 and 111 are elliptical, and button 112 is circular. (Note that a fourth button 113 protruding from the side of the housing, as seen in FIGS. 5 and 30 , may also be used to power the apparatus up or down, as well as accomplish other functions as well).
Alternatively, other means of user input, such as touch screen, touch pad, track ball, joystick or voice commands may replace or augment the buttons.
The internal circuitry 12 is illustrated in FIGS. 48-65 , and can include a main circuit board 43 , a user interface board 44 , USB chip 46 , and speaker 47 . In one embodiment, the main circuit board 43 contains at least two orifices 48 and 49 which are adapted to receive mounting member 50 and mounting member 51 . Mounting members 50 and 51 may be used to secure the main circuit board 43 to the heat sink 52 . Mounting members 50 and 51 may be screws, or pins or any similar type of member used to secure internal circuitry known in the art. FIG. 48 is a schematic of a circuit diagram of the main circuit board 43 and how it connects to the remaining components of the present invention.
As seen in FIG. 30 , heat sink 52 generally comprises a left sidewall 99 , and right sidewall 100 , and a front sidewall 104 extending between the left and right sidewall. In a preferred embodiment heat sink 52 may also contain a middle bridge 101 which connects the left sidewall 99 with the right sidewall 100 . Extending from the middle bridge and curving downwards is a hook member 102 . The hook member has an internal cavity 103 , which is adapted to receive the USB chip 46 . On the front sidewall 104 , and left and right sidewalls 99 and 100 , there may be cylindrical members 105 that are adapted to receive mounting screws 106 , and may include the use of threaded inserts. Mounting members 40 may be used to mount the scanner assembly 15 . In one embodiment, mounting members 40 may be screws. It will be appreciated that the photodiode assembly may be mounted by other means.
The heat sink capabilities might be enhanced by a fan or blower arranged in a way that would direct the air flow onto the heat sink and out of the housing. Additionally, a thermodynamic or thermoelectric heat pump may be employed between the heat-dissipating portions of the heat sink, to facilitate heat exchange. In a preferred embodiment, a heat shield 80 is mounted onto the top surface of the user interface board 44 .
Preferably being directly connected the main circuit board 43 , is the user interface board 44 . FIG. 50 is a schematic of a circuit diagram of the user interface board. The user interface board 44 contains the firmware which sends a graphic user interface to the display 14 , and stores the user's preferences. In one embodiment the interface board 44 is directly mounted to the top surface of the main circuit board. In one embodiment, the display 14 is directly mounted to the user interface board 44 , and may be a Liquid Crystal Display (LCD). It will be appreciated to those skilled in the art that an Organic Light Emitting Diode display (OLED) could work equally well. Alternatively, other means of information delivery may be used, such as lamp or LED indicators and audible cues. Some of the information that may be delivered to the user, other than the projection of vein images onto a patient's arm, may be visual cues also being projected on the patient's arm alongside the vein images, visual cues regarding additional information concerning the veins.
Mounted to the user interface board may be a keypad 13 . Keypad 13 , as noted previously, may be comprised of a plurality of control means which may include, but is not limited to, a plurality of buttons 77 . In a preferred embodiment, there may be three buttons used for controlling the apparatus—buttons 110 - 112 . Each of these buttons may have a first end 78 and a second end 79 . The first ends 78 of the plurality of buttons is adapted to be exposed through corresponding openings in the housing top section 17 , where they may be toggled by the user. The second end 79 of the buttons is adapted to be received by the user interface board 44 .
Also attached to the main circuit board is the USB chip 46 . USB chip mounts to the main circuit board 43 at a pin connection, and provides a pin connection for speaker 65 . The USB chip 46 is preferably mounted to the bottom surface of the main circuit board.
Also connected to the main circuit board is the scanner assembly 15 ( FIG. 42 ). The scanner assembly 15 generally includes a photodiode engine 53 , a photodiode board 54 , and a heat pipe 55 . In one embodiment, the photodiode engine 53 is directly mounted to the top surface of the photodiode board 54 , by one or more screws 56 , 57 , and 58 . In another embodiment, the bottom surface of the photodiode board is mounted to a foam fresen 59 . In the same embodiment, the foam fresen 59 is mounted to the bottom plate of the bottom section. In a preferred embodiment the foam fresen 59 has an orifice 69 which is adapted to receive the portion of the photodiode engine which houses the display light 62 . In a preferred embodiment the foam fresen 59 has a first arcuate cutout 75 at its front end and a second arcuate cutout 76 at its rear end. Arcuate cutouts 75 and 76 provide an arcuate surface for grommets 73 and 74 to be received.
The photodiode engine comprises a display light 62 ( FIG. 44 ). FIGS. 55, 61, and 65 are schematics of circuit diagrams relating to the photodiode engine and its peripheral connections. The display light 62 may be comprised of at least a red laser 63 and an infrared (IR) laser 64 . In a preferred embodiment red laser 63 may be a laser diode emitting light at a wavelength of 642 nm, and an infrared (IR) laser 64 that may emit light at a wavelength in the near infrared to be at 785 nm. Other combinations of wavelengths of more than two lasers may be used to enhance both the collection of the vein pattern and the display of the collected information. Red laser 63 projects an image of the vein pattern on the patient's skin. The laser diode has a wavelength of 642 nm, which is in the visible red region, but falls outside the spectral response range of photodiodes 60 and 61 . Red laser 63 illuminates areas with no veins, and does not illuminates areas with veins. This results in a negative image that shows the physical vein locations. Alternatively, the positive image may be used, where the red laser illuminates the vein locations and does not illuminate spaces between veins.
The red laser may be employed to project information other then vein locations, by means of turning on the laser or increasing its brightness when the laser beam is passing over the brighter parts of graphical or symbolic information to be projected, and turning off the laser or increasing its brightness when the laser beam is passing over the darker parts of graphical or symbolic information to be projected. Such information may include the vein depth, vein diameter, or the degree of certainty with which the device is able to identify the vein location, expressed, for example, through the projected line width 501 ( FIG. 66( a ) ), the length of the strokes in a dotted line 502 ( FIG. 66( b ) ), as a bar graph 503 ( FIG. 66( c ) ) or a numeric indication 504 ( FIG. 66( d ) ). It may also include user's cues 505 and 506 , respectively for optimizing the position of the device, such as choosing the correct tilt and distance to the target ( FIG. 66( e ) ).
Vein location and other information may also be displayed by projection means other than scanning laser, through the use of, for example, a DLP (Digital Light Processing) projector, a LCoS (Liquid Crystal on Silicon) micro-projector, or a holographic projector.
Additionally, the firmware of the photodiode board 54 may be programmed to recognize and modify display 14 , and projection by the display light 62 to represent a needle, catheter, or similar medical device 573 which has been inserted beneath a patient's skin and a part of it 573 a is no longer visible to the naked eye ( FIG. 70 ). The needle or medical apparatus may be made with, or coated with a material that absorbs or reflects a specified amount of the light from the IR laser 64 . Glucose is one example of a biomedical material which could be used as a coating to absorb or reflects a specified amount of an IR laser. Photodiodes 60 and 61 will detect the difference in reflection and absorption, and the photodiode board 54 may modify display 14 to show the needle or medical device. The photodiode board 54 may also be programmed to modify projection by the display light 64 so that the needle or medical device which has been inserted into the patient's skin is displayed.
More detailed information on the use of the laser light to view the veins can be found in U.S. patent application Ser. No. 11/478,322 filed Jun. 29, 2006 entitled MicroVein Enhancer, and U.S. application Ser. No. 11/823,862 filed Jun. 28, 2007 entitled Three Dimensional Imagining of Veins, and U.S. application Ser. No. 11/807,359 filed May 25, 2007 entitled Laser Vein Contrast Enhancer, and U.S. application Ser. No. 12/215,713 filed Jun. 27, 2008 entitled Automatic Alignment of a Contrast Enhancement System the disclosures of which are incorporated herein by reference.
The photodiode board 54 comprises one or more silicon PIN photodiodes, which are used as optical detectors. In a preferred embodiment, photodiode board 54 comprises at least two silicon PIN photodiodes 60 and 61 ( FIG. 42A ). The field of view (FOV) of the optical detectors is preferably arranged to cover the entire area reachable by light from IR laser 64 . FIGS. 8 and 10 are schematics of circuit diagrams which represent the photodiode board and its peripheral connections. In front of these photodiodes 60 and 61 are filters 120 and 121 ( FIG. 42A ) to serve as an optical filters that transmit infrared light, but absorb or reflect light in the visible spectrum. Mounted to photodiode 60 and 61 may be photodiode masks 66 and 67 . Photodiode masks 66 and 67 comprise a shaped orifice 68 which is adapted to be received by photodiode 60 and 61 respectively. In a preferred embodiment photodiode masks 66 and 67 are circular and are adapted to be received by the cylindrical protrusions 31 and 32 of the housing bottom section 18 . The photodiode board 54 is further comprised of an orifice 70 . The opening 70 may be rectangular and adapted to receive the portion of the photodiode engine which houses display light 62 . In a preferred embodiment the photodiode board 54 has a first arcuate cutout 71 at its front end, and a second arcuate cutout 72 at its rear end. Arcuate cutouts 71 and 72 provide an arcuate surface for grommets 73 to be received.
Other arrangements of optical detectors may be used too. In one possible arrangement, depicted on FIG. 67( a ) , the photodiode's field of view (FOV) 510 may be shaped by lenses-Fresnel lenses, curved mirrors or other optical elements 511 —in such way that the FOV extent on the patient's arm becomes small and generally comparable with the size of the IR laser spot 512 . This reduced FOV is forced to move synchronously with the laser spot by virtue of directing the optical path from the patient's arm to the photodiodes through the same scanning system 513 employed for the scanning of the laser beam, or through another scanning system, synchronous with the one employed for the scanning of the laser beam, so the FOV continuously overlaps the laser beam and follows its motion. Additional optical elements, such as a bounce mirror 514 , might be used to align the laser bean with FOV. Such an arrangement is advantageous in that it enables the photodiodes to continuously collect the reflected light from the IR laser spot while the ambient light reflected from the rest of the target generally does not reach the photodiodes.
Alternatively, the FOV of the photodiodes may be reduced in only one direction, and routed through the scanning system in such way that it follows the laser beam only in the direction where the FOV has been reduced, while in the other direction the FOV covers the entire extent of the laser scan ( FIG. 67( b ) ). Such FOV may be shaped, for example, by a cylindrical lens in front of a photodiode. As the laser spot 512 is moving along a wavy path defined by superposition of the fast horizontal scan and slow vertical scan, the FOV moves only vertically, which the same speed as the slow vertical scan, thus covering the scan line the laser spot is currently on. Such arrangement may be implemented, for example, by routing the FOV of the photodiode only through the slow stage of the scanning system 513 , but not its fast stage. Yet alternatively, the FOV may be shaped to follow the laser beam in close proximity without overlapping it ( FIG. 67( c ) ). In this case, the FOV still moves in sync with the laser spot 512 , but since it does not include the laser spot itself, the light reflected from the surface of the skin does not reach the photodiode. Instead, some portion of the light which penetrates the body, and, after scattering inside tissues, re-emerges from the skin surface some distance away from the laser spot, forming an afterglow area 515 , which is partly overlapped with FOV. Collecting only the scattered light while reducing overall signal strength, has the advantage of avoiding variations caused by non-uniform reflections from random skin features and may be helpful in discerning deep veins.
Multiple photodiodes may also be arranged in an array in such way that their individual FOVs cover the entire area illuminated by the IR laser. At any given moment, only the signals from one or more photodiodes whose FOV overlap the laser beam or fall in proximity to it may be taken into the account.
The photodiodes convert the contrasted infrared image returning from the patient into an electrical signal. The photodiode board 54 amplifies, sums, and filters the current it receives to minimize noise. The return signal of the photodiode engine 53 is differentiated to better facilitate discrimination of the contrast edges in the received signal received by photodiodes 60 and 61 . FIG. 71( a ) represents a typical signal collected from photodiodes 60 and 61 and digitized. Local peaks 580 correspond to the locations of veins in the patient body. FIG. 71( b ) represents the same signal after the differentiation. Since differentiation is known to remove the constant parts of the signal and amplify its changing parts, peaks 580 a can be easily found by comparison to ground reference (zero signal level of FIG. 71( b ) ). The photodiode board 54 also determines the locations where the infrared light has the lowest signal reflectivity using a scan system. These lower reflectivity locations indicate the vein locations.
Signal processing methods other than differentiation, including Digital Signal Processing (DSP) may be employed as well, such as Fast Fourier Transform (FFT), Finite Impulse Response (FIR) and Infinite Impulse Response (IIR) filtration. Additionally, more complex image processing algorithms might be used, for example based on continuity analysis, as the veins generally form continuous patterns. For example, FIG. 72 shows a few consecutive scan lines crossing a single vein 592 . While most lines produce distinctive signal peaks 590 , indicating the vein location, in some lines those picks might by masked by noise 591 . Still, connecting the vein location points derived from distinctive picks allows the algorithm to establish and display the true location of the vein.
To facilitate the use of DSP algorithms, the electronic circuitry to digitize the signal from the photodiodes and store it subsequently in some form of digital memory might be provided. Consequently, the display of the vein pattern by the red laser might be delayed with respect to the acquisition of said pattern with the IR laser. Such delay may vary from a small fraction of the time interval needed to scan the entire display area to several such intervals. If necessary, an intentional misalignment between the red and IR laser might be introduced, so the red laser can light up or leave dark the areas where the IR laser detected the lower or higher reflectivity, although the red laser beam would travel through those areas at different times than the IR laser.
The scan system employed by the apparatus 10 of the present invention uses a two dimensional optical scanning system to scan both the infrared and visible laser diodes. A dichroic optical filter element 125 in FIG. 44 allows laser diodes 63 and 64 to be aligned on the same optical axis and be scanned simultaneously. This allows for a minimal time delay in detecting the infrared reflected signal, and then re-projecting the visible signal.
The scan system employed by the apparatus 10 of the present invention has a horizontal and vertical cycle. Vertical scanning is driven in a sinusoidal fashion, and in one embodiment it occurs at 56.6 Hz, which is derived from 29 KHz sinusoidal horizontal scan. The Scan system is also interlaced. During a horizontal cycle the projection system is active only one half the horizontal scan system and blanked during the alternate half of the scan cycle. On the alternate vertical cycle the blanked and active portion of the horizontal scan is reversed. The top and bottom areas of the scan are blanked as well with a small area at the top of scan, located behind a mechanical shield for safety, reserved for execution of a laser calibration activity.
Alternative scan system might be used as well, such as those using a single scanning mirror deflectable in two orthogonal directions, or two uni-directional mirrors with smaller ratios of horizontal and vertical frequencies, such that the scan pattern forms a Lissajou figure (See http://www.diraedelta.co.uk/science/source/l/i/lissajous%20figures/source.html, and for animated figures, http://ibiblio.org/e-notes/Lis/Lissa.htm, which are incorporated herein by reference).
Various mechanical arrangements for scanning mirrors may be used. In one embodiment ( FIG. 68 ) the mirror 550 , made of glass, plastic or silicon, is attached to a free end of a cantilevered torsion fiber 551 , made of Blass or other linearly-deformable material, the other end of which is fixed to a base plate 552 . A magnet 553 , polarized in a direction perpendicular to the fiber, is attached to the fiber between the base plate and the mirror. A coil 554 may be positioned in close proximity to the magnet. The coil 554 may be used both for driving the mirror by virtue of energizing it with AC current, as well as for collecting the positional feedback by virtue of amplifying the voltage induced in the coil by magnet's oscillations. Both functions may be accomplished simultaneously, for example, by using one half of the mirror's oscillatory cycle for driving and the other half for collecting feedback. Alternatively, other means of driving the mirror, such as inducing torsional oscillation on the entire base plate by means of a piezo-electric element 555 , might be used. The magnet 553 and the coil 554 are used exclusively for feedback in this case.
The torsion mode of the fiber 551 may be higher than fundamental, meaning that at least one torsional node, i.e. a cross-section of the fiber which remains still during oscillations, is formed. Such nodes allows for generally higher oscillation frequency at the expense of generally lower oscillation amplitude.
Since high oscillation frequency is desirable to obtain high-resolution images at smooth video rates, the linear speed of the mirror's outer edges becomes quite high as well, leading to excessive dust buildup along those edges. To alleviate this problem, the edges of the mirror may be smoothed by either removing some mirror material 560 ( FIG. 69 ), or adding a layer of bevel-shaped coating 561 around the edges of the mirror.
Non-mechanical scanning systems, such as acousto-optic, electro-optic or holographic might be employed as well.
In a preferred embodiment, each scan line is divided into 1024 pixels numbered 0-1023. In pixel range 0-106, red laser 63 is at its threshold, and IR laser 64 is off. The term “threshold”, as applicable to lasers, means an inflection point on the laser Power-Current (P-I) curve, where the current becomes high enough for the stimulated emission (aka “lasing”) to begin. This point is marked Ith of FIG. 73 , which, while taken from the documentation of Sanyo Corp., is representative of the vast majority of laser diodes. In pixel range 107-146, red laser 63 is active, and IR laser 64 is at its threshold. In pixel range 182-885, red laser 63 is active, and IR laser 64 is on. In pixel range 886-915, red laser 63 is active, and IR laser 64 is off. In pixel range 916-1022, red laser 63 is at its threshold, and IR laser 64 is off. In pixel range 0-106, red laser 63 is at its threshold, and IR laser 64 is off.
Projection is accomplished by loading the appropriate compare registers in the complex programmable logic device, or CPLD. The content of the registers is then compared to the running pixel counter, generating a trigger signal when the content of a register matches the pixel count. The “left” register is loaded with the pixel count of when the laser should be turned off and the “right” register loaded with the pixel count of when the laser should be turned back on. The registers should be loaded on the scan line prior to the line when the projection is to occur. Projection is only allowed during the “Active” part of the red laser scan, i.e. between pixels 107 and 916 , as explained above.
To improve vein visibility it is important to maintain the laser spot of a proper size on the surface of the patient's skin. This may be accomplished by fixed laser-focusing optics, or by an auto-focusing system which adjusts the beam focusing in response to changes in the distance to the target.
Certain patient's veins or a portion of their veins might not be displayed well or at all. Causes for veins not be displayed include vein depth skin conditions (e.g. eczema, tattoos), hair, highly contoured skin surface, and adipose (i.e. fatty) tissue. The apparatus is not intended to be used as the sole method for locating veins, but should be used either prior to palpation to help identify the location of a vein, or afterwards to confirm or refute the perceived location of a vein. When using the apparatus qualified medical personnel should always follow the appropriate protocols and practices.
In one embodiment, when the user wishes to operate the apparatus, the user may apply a perpendicular force to the top surface of the side button 113 , or depress power button 112 to power the device. Once the device has been powered, the user can turn on the display light 62 by pressing and holding the top surface of the side button 113 for a set amount of time. In a preferred embodiment the photodiode board 54 has been programmed to activate the display light 62 after the user has held side button 113 for a half second.
Embedded in the user interface board 44 may be firmware, which supports the displaying, upon LCD 14 , of a menu system (see FIGS. 15-22 ). The menu system permits a user to access a plurality of features that the apparatus of the present invention can perform. The user can cycle through different display modes that the firmware has been programmed to transmit to the display by tapping the top surface of the side button 98 . The features embedded in the firmware can include a menu system, menu settings, display status. In one embodiment, the first LCD button 110 is programmed to access the menu mode ( FIG. 15 ). One of those features of the firmware permits labeling or naming of a particular apparatus, as seen in FIG. 20 . Such labeling may become advantageous in an environment where a medical service provider utilizes a plurality of the apparatus 10 , such as in an emergency room. The plurality of apparatus 10 may be maintained in a corresponding, plurality of rechargeable cradles 5 , which may be mounted to a bracket 200 , and secured thereto using fastening means 201 , as seen in FIG. 29 . Power to the cradles 5 may be supplied from an adapter 202 plugged into a wall outlet, with a power splitter 203 supplying power to each cradle 5 . Each of the plurality of apparatus 10 in this example may be appropriately labeled, “ER 1 ,” “ER 2 ,” . . . .
When the apparatus's 10 display light 62 is activated, the apparatus 10 can be used to locate veins. The user can access the scan function by navigating to it using the keypad 13 . The firmware will contain a feature which will allow the user to cycle through display settings using a menu system to optimize vein display for the current subject. When the display light 62 is deactivated, the display 14 remains available for viewing status and making configuration settings using the menu system.
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A portable vein viewer apparatus may be battery powered and hand-held to reveal patient vasculature information to aid in venipuncture processes. The apparatus comprises a first laser diode emitting infrared light, and a second laser diode emitting only visible wavelengths, wherein vasculature absorbs a portion of the infrared light causing reflection of a contrasted infrared image. A pair of silicon PIN photodiodes, responsive to the contrasted infrared image, causes transmission of a corresponding signal. The signal is processed through circuitry to amplify, sum, and filter the outputted signals, and with the use of an image processing algorithm, the contrasted image is projected onto the patient's skin surface using the second laser diode. Revealed information may comprise vein location, depth, diameter, and degree of certainty of vein locations. Projection of vein images may be a positive or a negative image. Venipuncture needles may be coated to provide visibility in projected images.
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BACKGROUND
The subject matter of the invention is an embroidery module for a free-arm sewing machine.
Free-arm sewing machines for home use have a relatively small work surface, in order also to be able to process tubular work pieces, such as sleeves, etc. For better support of larger work pieces, so-called slide-on extension tables, which have a U-shaped configuration and which enclose the free arm on three sides, are frequently supplied with the sewing machine. This significantly larger work and support surface, however, prevents the sewing or embroidering of tubular sewing material.
The work surface can also be expanded for large work pieces by docking an embroidery module, which is used for driving and supporting an embroidery hoop. Here, it is disadvantageous that after the work is performed, the slide-on extension table or the embroidery module must be removed again, in order to be able to perform different work on the sewing machine.
SUMMARY
One objective of the present invention is to create an embroidery module, which can be used both for its main purpose, namely the driving and guiding of an embroidery hoop, but also continuously as an enlarged work surface, without having to limit the possibilities of the free-arm sewing or free-arm embroidery for tubular work pieces when the embroidery module is docked.
This objective is met by the present invention.
This objective is achieved without issue in various respects by the configuration of the embroidery module according to the invention. Here, not only is the use of the embroidery module as an expanded work surface advantageous thanks to the embroidery hoop support that can be completely removed from the embroidery module, but also an embroidery hoop support for larger embroidery hoops, which is consequently long due to the large edge length of such embroidery hoops, can be stored separately from the embroidery module. For most sewing work, the embroidery module can always remain coupled to the sewing machine without the embroidery hoop support or it is advantageous to keep this module docked to the machine. For individual applications, in which the properties of the free arm are required, the embroidery module can also remain docked.
On the other hand, the latter construction can be removed from the machine when only tubular work pieces are to be processed for a long time, in contrast to embroidery hoop drives connected permanently to the machine. The mounting of the embroidery hoop support in guides, which are located at the sides of the embroidery module, prevents dust or sewing instruments, e.g., needles or cut threads, from reaching into the guide rails. In addition, the slot-free surface of the embroidery module forms a closed material support that does not interfere with the movement of the material when sewing or embroidering.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail with reference to an illustrated embodiment. Shown are:
FIG. 1 is a perspective view of an embroidery module with the embroidery hoop support removed;
FIG. 2 is a perspective bottom view of an embroidery module with the embroidery hoop support removed;
FIG. 3 a is a perspective view of a sewing machine with docked embroidery module;
FIG. 3 b is a side view of the sewing machine with docked embroidery module;
FIG. 3 c is a top view of a sewing machine with docked embroidery module;
FIG. 4 a is a perspective view of the sewing machine with docked embroidery module and coupled slide-on extension table;
FIG. 4 b is a side view of the sewing machine with coupled slide-on extension table;
FIG. 4 c is a top view of a sewing machine with coupled slide-on extension table;
FIG. 5 a is a perspective view of the sewing machine and the embroidery module with coupled embroidery hoop support, as well as the embroidery hoop and the slide-on extension table;
FIG. 5 b is a side view of the sewing machine and the embroidery module with coupled embroidery hoop support, as well as embroidery hoop with slide-on extension table;
FIG. 5 c is a top view of a sewing machine and the embroidery module with coupled embroidery hoop support, as well as embroidery hoop with slide-on extension table;
FIG. 6 a is a perspective view of the sewing machine, the embroidery module, and coupled embroidery hoop support without slide-on extension table;
FIG. 6 b is a side view of the sewing machine, the embroidery module, and coupled embroidery hoop support without slide-on extension table; and
FIG. 6 c is a top view of a sewing machine and the embroidery module with coupled embroidery hoop support without slide-on extension table.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embroidery module 1 shown in FIGS. 1 and 2 includes a main body 3 with an essentially rectangular outline. A recess 5 , which can be open at the bottom or can have an approximately v-shaped or cylindrical shell-shaped base 7 , as in the shown configuration, is visible on one of the two narrow sides. Underneath the base 7 , a base plate 9 extending over the entire main body 3 can be attached. In the two longer side surfaces 8 , 10 of the embroidery module 1 , slots 11 extending on the side of the narrow-side recess 5 up to or only approximately up to the end of the embroidery module 1 are formed parallel to its upper surface. In contrast, on the opposite narrow side, they are open. Within the embroidery module 1 are drives, such as toothed belts, round belts, metal bands, cords, or shafts, which can transport an embroidery hoop support 13 guided in the X-direction exactly parallel through the use of suitable couplings. The drives for the embroidery hoop support 13 , which are not shown in the figures, because they are not visible, are driven by at least one first electric motor inserted within the embroidery module 1 . The embroidery hoop support 13 is connected to a transport device located behind the slots 11 by brackets 15 (cf. FIG. 2 ), which engage through the slots 11 into the not-described and not-visible couplings. The brackets 15 are dimensioned so that an intermediate space exists between the elongated housing 17 of the embroidery hoop support 13 and the work surface 19 on the embroidery module 1 . That is, the embroidery hoop support 13 or the embroidery hoop 25 does not contact the surface of the embroidery module 1 .
In the housing 17 of the embroidery hoop support 13 , a second drive motor for an embroidery hoop adapter 21 is provided, which is mounted so that it can move in the Y-direction in the embroidery hoop support 13 , in the cylindrical section 20 in the center in FIGS. 1 and 2 . The embroidery hoop adapter 21 can have, for example, bores 23 , in which an embroidery hoop 25 can be fixed (cf. FIGS. 5 and 6 ).
Below, the embroidery module 1 is described in more detail in combination with a household sewing machine 27 , i.e., docked to such a machine.
In FIGS. 3 a to 3 c , it can be seen that the embroidery module 1 is fixed at the end along the edge Q to the end surface of the base plate 29 of the sewing machine 27 and that the free arm 31 projects only by a small amount a into the recess 5 on the embroidery module 1 . The other area of the recess 5 in the embroidery module 1 is not filled by a part of the sewing machine 27 , but instead is used as a free space 33 for inserting, e.g., tubular sewing material over the free arm 31 . In the arrangement described now ( FIGS. 3 a - c and 4 a - c ), the embroidery module 1 is used solely as an enlarged work surface, i.e., as a sewing-material support especially when sewing large surface area work pieces. To further expand the sewing-material support, a slide-on extension table 35 can be attached, which can also be docked to the free arm 31 of the sewing machine without an embroidery module 1 . Therefore, on one hand the free space 33 formed by the recess 5 is closed at the top and on the other hand the contact surface on the sewing machine is further expanded (cf. FIGS. 4 a to 4 c ) in front of and behind the free arm 31 (viewed in the direction of sewing). In this arrangement, it is obvious that the processing of tubular work pieces is not possible. For this purpose, as shown in FIGS. 3 a to 3 c , the slide-on extension table 35 must be removed. So that the slide-on extension table 35 forms a plane with the surface of the free arm 31 when the embroidery module is docked, the surface of the embroidery module 1 lies at the height h 2 , i.e., offset by the thickness d of the slide-on extension table ( 35 ), deeper than the surface of the free arm 31 , which lies at the height h 1 (h 1 −h 2 =d). This difference in height between the surface of the free arm 31 and that of the embroidery module 1 does not interfere with sewing or embroidering without the slide-on extension table 35 . In contrast, these steps optimize the accessibility of the free space 33 between the embroidery module 1 and the free space 31 .
In FIGS. 5 a - 5 c and to 6 a - 6 c , the embroidery hoop support 13 is placed on the embroidery module 1 . This is supported by the two brackets 15 , which engage in the side slots 11 on the foundation 3 of the embroidery module 1 . The embroidery hoop 25 is fixed on the embroidery hoop support 13 , with which sewing material 37 held in tension on the hoop is mounted so that it can move via a computer-assisted program under the needle (not shown) of the sewing machine 27 in the x-direction and the y-direction. The embroidery hoop 25 here lies on the slide-on extension table 35 , as is shown in FIGS. 4 a to 4 c.
In the representation according to FIGS. 6 a to 6 c , the embroidery hoop 25 lies directly on the surface of the free arm 31 . That is, the free space 33 , formed by the recess 5 , is not closed at the top and the free arm 31 itself is free at the side. Consequently, tubular work pieces or also hemispherical work pieces, such as caps, can also be tensioned in the embroidery hoop 25 . The non-tensioned part of this sewing material can move without interference around the free arm 31 during the sewing or embroidering.
In the four embodiments of the embroidery module 1 according to the invention, the module does not have to be removed from the sewing machine 27 . Consequently, all of the work performed on a sewing machine 27 can also be performed when the embroidery module 1 remains docked. A lot of sewing work, in which the embroidery module 1 is not needed, can benefit from this module, however, when it is docked for sewing, quilting, or embroidery. The embroidery hoop support 13 , which is not needed for work without the embroidery hoop 25 , can be removed easily from the embroidery module 1 without a tool and placed to the side.
LEGEND
1 Embroidery module
3 Main Body of 1
5 Recess
7 Base of 5
8 Side surface
9 Base plate
10 Side surface
11 Slot
13 Embroidery hoop support
15 Brackets
17 Housing
19 Work surface on the embroidery module
20 Cylindrical section
21 Embroidery hoop adapter
23 Bores
25 Embroidery hoop
27 Sewing machine
29 Base plate of 27
31 Free arm
33 Free space
35 Slide-on extension table
37 Sewing material
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An embroidery module ( 1 ) is provided that is attached (docked) to the base plate ( 29 ) of a sewing machine ( 27 ) and supplied with power and control commands from the machine electronics. A free space ( 33 ), which permits the insertion of tubular work pieces around the free arm ( 31 ), is created between the embroidery module ( 1 ) and a front end of the free arm ( 31 ). The embroidery module ( 1 ), with or without an embroidery hoop support ( 13 ), can remain docked for all sewing, embroidery, and quilting work on the sewing machine ( 27 ).
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The present application is a continuation patent application of U.S. patent application No. 13/841,881, filed on Mar. 15, 2013, the benefit of which is claimed and the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to the separation of components in a multi-phase flow stream. More specifically, it relates to restructuring flow regimes by a flow shaping apparatus so that the majority of a particular fluid component in a flow stream is located in a certain area of the flow stream, which allows for effective separation of the various fluid components.
BACKGROUND OF THE INVENTION
A gas-liquid two phase flow stream includes a mixture of different fluids having different phases, such as air and water, steam and water, or oil and natural gas. Moreover, the liquid phase of a fluid flow stream may further comprise different liquid components, such as oil and water. A gas-liquid two phase flow takes many different forms and may be classified into various types of gas distribution within the liquid. These classifications are commonly called flow regimes or flow patterns and are illustrated in FIGS. 1A-1E . Bubble flow as illustrated in FIG. 1A is typically a continuous distribution of liquid with a fairly even dispersion of bubbles in the liquid. Slug or plug flow as illustrated in FIG. 1B is a transition from bubble flow where the bubbles have coalesced into larger bubbles with a size approaching the diameter of the tube. Churn flow as illustrated in FIG. 1C is a pattern where the slug flow bubbles have connected to one another. In annular flow as illustrated in FIG. 1D , liquid flows on the wall of the tube as a film and the gas flows along the center of the tube. Finally, in wispy annular flow as illustrated in FIG. 1E , as the liquid flow rate is increased, the concentration of drops in the gas core increases, leading to the formation of large lumps or streaks of liquid.
It is often desirable to separate the gas and liquid components of a fluid from one another to enable proper operation of systems, such as certain types of liquid pumps. Conventional vertical or horizontal gas-liquid separators are available to separate gas from liquid. Conventional separators typically employ mechanical structures, wherein an incoming fluid strikes a diverting baffle which initiates primary separation between the gas and liquid components. Mesh pads or demister pads are then used to further remove suspended liquid. The sizing of a separator and the particular characteristics of the separator is dependent upon many factors, which may include, the flow rate of the liquid, the liquid density, the vapor density, the vapor velocity, and inlet pressure. Vertical separators are typically selected when the vapor/liquid ratio is high or the total flow rate is low. Horizontal separators are typically preferred for low vapor/liquid ratio or for large volumes of total fluid.
One application of these types of separators is in oil and gas drilling operations. Specifically, a mud-gas separator is used when a kick is experienced in a wellbore during drilling operations. A kick is the flow of formation fluids into the wellbore during drilling operations. If a kick is not quickly controlled, it can lead to a blow out. As part of the process for controlling a kick, the blow-out preventors are activated to close the wellbore and wellbore fluids are slowly circulated out of the wellbore while heavier drilling fluids are pumped into the wellbore. A mud gas separator is used to separate natural gas from drilling fluid as the wellbore fluid is circulated out of the wellbore. Often times, however, prior art separators, have limited capability to process flow streams with high volumes and/or high flow rates, such as those characteristic of wellbores.
Of course, separators are also used in the production of oil and gas to separate natural gas from oil that is being produced. Additionally, there are many other applications that require the use of gas-liquid separators. For example, when supplying fuel to ships, known as bunkering, air is often entrained in the fuel, causing an inaccurate measurement of the transferred fuel. Likewise, in oil production or production of other liquids, transferring or conveying a liquid may result in the liquid acquiring entrained gas during that process, a result observed in pipelines with altered terrains. In this regard, entrained gasses can prevent the accurate measurement of a liquid product, whether it is fuel transferred during bunkering or a liquid flowing in a pipeline.
SUMMARY OF THE INVENTION
One aspect of the invention relates to shaping multi-phase mixed flow using a curvilinear flow line formed in multiple loops or coils prior to separation of a fluid component from the flow path. Shaping the multi-phase flow into a curvilinear path will allow centrifugal force to more readily force the heavier, denser liquid to the outside or outer diameter wall of the flow shaping line in the curved path and allow the lighter, less dense vapor or gas to flow along the inside or inner diameter wall of the flow shaping line. In certain embodiments, once a flow regime has been restructured within the flow line, the flow component collected adjacent a particular wall of the line can be removed. For example, in flow streams characterized by a larger liquid component, the gas component of a liquid-gas flow stream will collect along the inner diameter wall of the curved flow shaping line, where the gas can be drawn or driven into an exit port located on the inner wall, thereby permitting a majority, if not all, of the gas, along with a low amount of liquid, to be sent to a conventional gas-liquid separator. The separated fluid will have a comparatively higher ratio of gas to liquid than the primary flow stream in the flow line, but will pass into the conventional gas separator at a flow rate much lower than the total flow rate within the flow shaping line. This permits for efficient separation of the gas from the liquid with the use of a smaller, more economical conventional gas-liquid separator than what would have been required for the full flow stream and/or higher flow rates.
In certain embodiments, a curvilinear flow line, whether in the form of a single loop or multiple loops, may be utilized in conjunction with a sensor for controlling an adjustable valve. In each case of multiple loops, the loops in the flow line permit an extended residence time of a flow stream through the system. A sensor disposed along the flow path is utilized to estimate a property of the flow 12 , such as for example, the percentage or “cut” of one or more components of the flow steam. The adjustable valve is positioned sufficiently downstream so that the valve can be timely adjusted based on the measurement from the sensor. For example, a sensor measuring cut can be utilized to adjust the position of a weir plate in the flow stream, thereby increasing or decreasing the amount of fluid separated from the flow stream. Although the sensors as described herein will be primarily described as measuring the cut, other types of sensors may also be utilized. Likewise, the type of cut sensors are not limited to a particular type, but may include the non-limiting examples of interface meters; optics or capacitance sensors. The extended residence time of the flow stream in the multi-loop system permits the valve to be adjusted once the cut is determined, thereby enhancing separation of fluid components once the flow stream has been restructured in accordance with the invention. The adjustable valve may be, for example, be a weir plate, foil or similar structure that can be used to draw off or separate one component of the flow stream. Other types of adjustable valves may also be utilized.
In certain embodiments of a multi-loop system, the primary diameter of one or more loops or coils generally disposed along an axis may be altered along the length of the axis to control the flow rate through the system. In certain embodiments, the flow line will include a plurality of loops formed along an axis, with each successive loop having a smaller primary diameter than the preceding loop, such that the velocity of the flow stream within the flow line increases along the axis while maintaining flow regime separation. Likewise, in certain embodiments, the flow line will include a plurality of loops formed along an axis, with each successive loop having a larger primary diameter than the preceding loop, such that the velocity of the flow stream within the flow line decreases along the axis.
In certain embodiments of a multi-loop system, two sets of loops or coils may be utilized along a flow path. The first set of loops will function to separate a component, such as gas, as described above. The second set of loops functions to address any gas that remains in the flow stream. In certain embodiments, prior to introduction of the flow stream into the second set of loops, the flow stream may be agitated so as to thereafter enhance flow regime reshaping as described above.
Additionally, a fluid guiding surface may be placed on the inner wall of the flow shaping line at the exit port to further aid in directing the gas to flow to the conventional gas separator.
Furthermore, the liquid return from the conventional gas-liquid separator may be arranged in close downstream proximity to the exit port on the inner wall of the flow shaping line. The close proximity of the liquid return and the exit port allows the use of a venturi, nozzle or other restriction located adjacent the liquid return in the flow shaping line just downstream of the exit port. The venturi, nozzle or other restriction accelerates the velocity of the liquid in flow shaping line as it flows across the exit port. This acceleration of the liquid helps to pull the liquid out of the conventional gas-liquid separator. In addition, the acceleration of the liquid within the flow shaping line helps to prevent any solids that may be present in the gas-liquid flow from entering the exit port and it helps to lower the amount of liquid that enters the exit port and thus enters the conventional separator.
In certain embodiments, a heater may be disposed along a flow stream prior to flow regime reshaping in order to cause a phase change of at least a portion of the fluid within the flow stream. For example, certain liquid hydrocarbons in flow stream may be converted to gas under an applied heat in order to enhance separation of the hydrocarbon from the flow steam as described above. Such a heater may be utilized with curvilinear flow line having either single and multi-loops.
Likewise, in certain embodiments, a curvilinear flow line having either single and multi-loops may be utilized in conjunction with a liquid-liquid phase separator. The liquid-liquid phase separator is preferably deployed down stream of the exit port and is disposed to separate different density liquids from one another. In certain embodiments, the liquid-liquid phase separator may be adjustable and utilized in conjunction with a sensor. The sensor is disposed along the flow path downstream of the gas exit port and is utilized to estimate the percentage or “cut” of various liquids remaining in the flow steam. The phase separator can be adjusted based on the cut. The phase separator may include, for example, an adjustable weir plate, adjustable foil, adjustable valve or similar adjustable mechanism. In one embodiment, the phase separator may include an adjustable valve in the form of rotatable ball having two flow passages therethrough. Rotation of the ball adjust the positions of the flow passages relative to the liquid-liquid flow stream, exposing more or less of a particular passage to the flow steam. Other types of adjustable valves may also be utilized.
In another embodiment of the invention particularly suited for flow streams with a high gas content, i.e., “wet gas”, a flow channel is formed along at least a portion of the inner diameter wall of a curvilinear flow line as described herein. The liquid within the wet gas will collect in the flow channel and can be drained off from the primary flow stream.
In another embodiment of the invention, the gas-liquid separator includes a variable position gas control valve that maintains level control of a vessel and establishes a constant flow pressure throughout the system.
The invention therefore allows a multi-phase fluid to be effectively separated with the use of a smaller conventional separator than was previously possible. The invention accomplishes this without using additional complex mechanical devices and thus will operate efficiently and reliably.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present disclosure and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying figures, wherein:
FIGS. 1A-1E illustrate a cross-sectional view of various flow regimes of two phase gas-liquid flow.
FIG. 2 illustrates a cross-sectional view of an embodiment of separation apparatus with a flow regime modification loop/coil and a liquid-liquid phase splitter.
FIG. 3 illustrates an elevation view of the embodiment of the separation apparatus with a plurality of flow regime modification loops/coils of descending cross-sectional diameter.
FIG. 4 illustrates an elevation view of the embodiment of the separation apparatus with a plurality of flow regime modification loops/coils having successively decreasing diameters and a liquid-liquid phase separator.
FIG. 5 illustrates an elevation view of the embodiment of the separation apparatus with a plurality of flow regime modification loops/coils having substantially the same diameters and a liquid-liquid phase separator.
FIG. 6 a illustrates an elevation view of the embodiment of the separation apparatus with two sets of flow regime modification loops/coils of FIG. 4 .
FIG. 6 b illustrates an elevation view of the embodiment of the separation apparatus with two sets of flow regime modification loops/coils of FIG. 5 .
FIG. 7 is an elevation view of a multi-phase flow separation apparatus utilizing two sets of loops/coils of FIG. 4 , arranged in series.
FIG. 8 illustrates a cross-sectional view of a flow regime modification loop/coil for wet gas processing.
FIG. 9 illustrates a cross-sectional view of another embodiment of a liquid-liquid phase splitter with an adjustable valve.
FIG. 10 illustrates a cross-sectional view of a gas control valve in a gas separation tank.
FIG. 11 illustrates an elevation view of another embodiment of separation apparatus deployed in oil and gas drilling operations.
FIG. 12 illustrates an elevation view of another embodiment of separation apparatus deployed in fuel bunkering operations.
DETAILED DESCRIPTION
In the detailed description of the invention, like numerals are employed to designate like parts throughout. Various items of equipment, such as pipes, valves, pumps, fasteners, fittings, etc., may be omitted to simplify the description. However, those skilled in the art will realize that such conventional equipment can be employed as desired.
FIG. 2 illustrates a cross-sectional view of an embodiment of a separation apparatus 10 . In an exemplary embodiment, the separation apparatus 10 is in fluid communication with a main flow line 15 in which a multi-phase flow 12 is traveling. The multi-phase flow 12 could be any type of multiphase gas-liquid flow regime or flow pattern, such as, for example, bubble flow, slug or plug flow, churn flow, annular flow or wispy annular flow. Moreover, the multi-phase flow may include two components within a single phase, such as water and oil within the liquid phase. The multi-phase flow 12 within main line 15 is directed into a curvilinear flow path 16 in a flow shaping line 17 . In certain embodiments, such as is illustrated in FIG. 2 , the curvilinear flow path 16 is substantially in the form of a loop having a circular shape, although the curvilinear flow path may have other curvilinear shapes. In any event, the curvilinear flow path 16 of flow shaping line 17 creates an increased distribution of a first phase 22 , such as gas, along the inner wall 24 of the flow shaping line 17 . The increased distribution of this first phase 22 along the inner wall 24 of the flow shaping line 17 results in part by the relatively heavier and denser second phase 18 , such as a liquid, of flow 12 being forced to the outer wall 20 of the flow shaping line 17 due to centrifugal force of curvilinear flow path 16 , while the lighter first phase 22 is driven to the inner wall 24 . The flow shaping line 17 may be disposed in any orientation, including substantially in a vertical plane or a horizontal plane. In embodiments with a vertical or partly vertical orientation of the flow shaping line 17 , gravitational effects may also aid in increasing the distribution of the first phase 22 on the inner wall 24 of the flow shaping line 17 .
As the multi-phase flow 12 continues to travel through the curvilinear flow path 16 of flow shaping line 17 , the multi-phase flow 12 forms a flow path that exhibits a high concentration of gas 22 along the inner wall 24 of the flow shaping line 17 . In the embodiment shown in FIG. 2 , at location 26 , which is approximately 315 degrees around shaping line 17 (or 45 degrees from the vertical), the separation of gas 22 from liquid 18 has reached a degree that gas 22 primarily occupies the space adjacent the inner wall 24 of the flow shaping line 17 . As seen in FIG. 3 , which is a cross section 3 - 3 of the flow shaping line 17 and multi-phase flow 12 at location 26 , the gas 22 occupies mainly the inner wall 24 of the circular flow path 16 of the flow shaping line 17 while the liquid 18 primarily travels along the outer wall 20 .
With gas-liquid flow 12 forming a more stratified flow regime, or at least the distribution or volume of gas near the inner wall 24 of the flow shaping line 17 has increased at the point of location 26 , the gas 22 may be effectively bled off from the gas-liquid flow 12 at an outlet port 28 positioned along the inner wall 24 of the flow shaping line 17 , preferably along a curvilinear portion of flow shaping line 17 . In this regard, although outlet port 28 may be positioned anywhere along flow path 16 , it is preferably selected to be at a point where substantial separation of gas from liquid has occurred. Thus, in one preferred embodiment, the outlet port 28 is downstream of location 26 . At about a location 26 , which is approximately at an angle of approximately 45 degrees from a vertical axis 74 or otherwise, approximately 315 degrees about a circular flow path, it has been found that the concentration, separation or stratification of the gas 22 from the liquid 18 is at a point that gas 22 occupies a greater volume of space adjacent the inner wall 24 of the main line 15 than liquid 18 . In other embodiments, the outlet port 28 may be located between generally 45 degrees from the vertical and generally zero degrees with the vertical. While location 26 is illustrated at approximately 315 degrees around flow shaping line 17 and has been found to be a point where a substantial volume of gas has been driven to inner wall 24 , location 26 is used for illustrative purposes only. In this regard, in configurations with multiple loops formed by flow shaping line 17 , the outlet port 28 may be disposed along an inner wall of any one of the loops, including the first loop, the last loop or an intermediate loop.
In an exemplary embodiment, a fluid guiding surface 30 is located at the outlet port 28 . In certain embodiments, a fluid guiding surface 30 a may be located on the inside diameter 32 of the inner wall 24 of the flow shaping line 17 upstream of the outlet port 28 . The fluid guiding surface 30 includes a downstream end 36 that curves around the corner 37 located at the junction of the outlet port 28 and the flow shaping line 17 . The gas 22 follows the contour of the fluid guiding surface 30 a and the gas 22 will follow the curve of the downstream end 36 into the outlet port 28 . In another embodiment, a fluid guiding surface 30 b may comprise a weir plate, foil or similar separation mechanism disposed to direct gas 22 into outlet port 28 . The fluid guiding surface 30 b functions to guide the gas 22 into the outlet port 28 . In certain embodiments, fluid guiding surface 30 b is adjustable in order to adjust the position of fluid guiding surface 30 b , and hence, the first phase cut removed from flow stream 12 . A sensor 34 may be disposed to operate in conjunction with and control adjustable fluid guiding surface 30 b based on a measured property of the flow stream 12 , such as cut. Although sensor 34 may be located anywhere along main line 15 or flow shaping line 17 , it has been found that sensor 34 is preferably separated a sufficient distance from outlet port 28 to permit the position of adjustable fluid guiding surface 30 b to be adjusted once the cut of flow 12 has been determined. Likewise, in certain embodiments, sensor 34 is disposed along flow shaping line 17 at a point where substantial phase separation has taken place, such as at 26 , thereby increasing the accuracy of sensor 34 .
An amount of liquid 18 ′ from the gas-liquid flow 12 will also be carried into the outlet port 28 thus forming a new gas-liquid flow 40 which includes a much lower percentage of liquid 18 ′ compared to the liquid 18 in gas-liquid flow 12 . The new gas-liquid flow 40 from outlet port 28 is then directed into a conventional gas-liquid separator 38 , as shown in FIG. 2 , for further separation of the gas and liquid. Outlet port 28 is connected to the conventional gas-liquid separator by separator inlet line 33 . The gas-liquid separator 38 contains a gas exit 39 to permit removal of gas 22 separated from flow stream 12 . The gas-liquid separator 38 also contains a liquid exit 41 . In certain embodiments, liquid exit 41 that may be in fluid communication, via a line 44 , with flow shaping line 17 or a subsequent flow line 43 disposed at the end of the flow shaping line 17 . Those skilled in the art will appreciate that separation apparatus 10 is shown as integrated with gas liquid separator 38 , but can be a completely separate structure.
In an exemplary embodiment, the liquid inlet port 42 is in close downstream proximity to outlet port 28 with a venture or similar restriction 46 formed therebetween along the flow path of liquid 18 flow. The restriction 46 accelerates the velocity of the liquid 18 as it flows across the liquid inlet port 42 . This acceleration of liquid 18 lowers the pressure of the liquid 18 flow in the primary flow path below that of the liquid 18 ′ in line 44 , thereby drawing liquid 18 ′ out of the conventional gas-liquid separator 38 . In addition, the acceleration of the liquid 18 facilitates separation of gas from liquid within flow shaping line 17 , minimizes the likelihood that any solids present in the gas-liquid flow 12 will enter outlet port 28 , and minimizes the amount of liquid 18 that enters the outlet port 28 .
In certain preferred embodiments, venturi 46 is adjustable, permitting the velocity of the flow therethrough, and hence the pressure drop across the venturi 46 , to be adjusted in order to control the amount of liquid 18 ′ drawn from conventional gas-liquid separator 38 . This in turn, permits the pressure of the gas within gas-liquid separator 38 , as well as the proportional amounts of liquid and gas therein, to be controlled. This is particularly desirable when gas void fraction to liquid is a higher percentile. To eliminate bypass of gas that might pass extraction point 28 .
As mentioned above, the efficient first step in the separation of the gas 22 from the liquid 18 significantly decreases the amount of liquid 18 entering the conventional gas-liquid separator 38 . This allows for the use of much smaller size conventional gas-liquid separators than would have previously been possible for a given flow rate and/or flow volume.
While circular flow path 16 is shown as positioned in a vertical plane, in another embodiment the circular flow path 16 could be in a horizontal plane (see FIG. 12 ) or in a plane with an inclination between horizontal and vertical.
In certain embodiments, as further illustrated in FIG. 2 , a phase splitter 50 is in fluid communication with flow shaping line 17 to receive the liquid 18 flow therefrom. Phase splitter 50 may be in direct fluid communication with flow shaping line 17 or may be in communication with a flow line 43 disposed between the phase splitter 50 and flow shaping line 17 . In this regard, a flow line 43 may be utilized to stratify multiple liquid components within liquid 18 by stabilizing the fluid flow. For example, flow line 43 may be horizontally disposed so that liquids 18 a with a first density, such as oil, separate from liquids 18 b with a second density, such as water, by virtue of gravitational effects acting thereon. Alternatively, additional loops in flow shaping line 17 may be utilized to stratify the liquid components 18 a , 18 b.
Phase splitter 50 includes a housing having a liquid inlet 52 for receipt of liquid 18 , as well as a first liquid outlet 54 and a second liquid outlet 56 . A weir plate, foil or similar separation mechanism 58 is disposed within phase splitter 50 to direct a portion of the liquid 18 into first outlet 54 and allow a portion of the liquid 18 to pass into second outlet 56 . For example, weir plate 58 may be disposed to direct a substantial portion of liquid component 18 b into first outlet 54 , while allowing liquid component 18 a to pass over weir plate 58 into second outlet 56 . In this way, separation apparatus 10 may be used not only to separate gas from liquid, but also to separate liquid from liquid in instances where gas and multiple liquids comprise flow stream 12 .
In certain embodiments, separation mechanism 58 may be adjustable in order to adjust the position of separation mechanism 58 , and hence, the cut of liquid removed from liquid 18 . Non-limiting examples of an adjustable separation mechanism 58 include an adjustable valve, adjustable weir plate or adjustable foil. A sensor 60 may be disposed to work in conjunction with and control an adjustable separation mechanism 58 based on a measured property of liquid 18 , such a cut. Although sensor 60 may be located anywhere along main line 15 or flow shaping line 17 or line 43 , it has been found that sensor 60 is preferably separated a sufficient distance from separation mechanism 58 to permit the position of separation mechanism 58 to be adjusted once the property of flow 12 has been determined. Likewise, in certain embodiments, sensor 60 is disposed along flow shaping line 17 or line 43 at a point where substantial liquid stratification has taken place, thereby increasing the accuracy of sensor 60 . In certain embodiments, sensor 34 and sensor 60 may be a single sensor utilized for multiple functions, such as to identify the cut of gas, a first liquid and a second liquid in flow 12 .
Turning to FIG. 4 , other embodiments of the invention are illustrated. In certain embodiments, the curvilinear flow path 16 is substantially in the form of a plurality of loops L 1 . . . L i , each loop characterized by a diameter D 1 . . . D i that together comprise flow shaping line 17 . The loops L are disposed along an axis 62 . In certain embodiments, the diameter D of the loops L may remain substantially constant along the length of axis 62 , while in other embodiments, the diameter of the loops may increase or decrease, either randomly or successively. In the illustrated embodiment, the diameter D of successive loops decrease along the length of the flow shaping line 17 from the first end 64 to the second end 66 of flow shaping line 17 .
The plurality of loops L may be provided to develop the increased concentration of the gas 22 on the inner wall 24 of the flow shaping line 17 . Moreover, the plurality of loops L increases the residence time of the flow 12 or liquid 18 through flow shaping line 17 . It may be desirable, for example, to increase residence time of the flow 12 or liquid 18 through the system 10 in order to measure the flow or liquid with sensors, such as the sensors 34 , 60 described above, and make adjustments to adjustable mechanisms 30 b , 58 based on the measurements prior to the flow 12 or liquid 18 reaching the adjustable mechanism. For example, the phase splitter 50 may be adjusted to separate liquid 18 into multiple phases, or the foil 30 b may be adjusted to separate gas 22 from flow 12 .
In this same vein, it may be desirable to alter the rate of the flow 12 or liquid 18 through system 10 . This is achieved by increasing or decreasing the diameter D of the loops L to achieve a particular flow rate for a particular deployment of system 10 . In one embodiment, for example, the diameter D of the loops L is decreased, resulting in an increase in velocity of the flow 12 from first end 64 to second end 66 which thereby results in greater centrifugal force and increased concentration of the gas 22 on the inner wall 24 of the flow shaping line 17 .
Sensors 34 and 60 may be disposed anywhere along the flow path of system 10 as desired. Likewise, outlet 28 along inner wall 24 may be positioned anywhere along flow shaping line 17 , the position being selected as desired based on the components of flow 12 . Thus, outlet 28 may be positioned in the first loop L 1 or a subsequent loop L, as illustrated. Likewise, liquid inlet port 42 may be in fluid communication with flow shaping line 17 or line 43 at any point in order to reintroduce liquid 18 ′ from separator 38 back into the main liquid 18 stream.
FIG. 4 also illustrates an optional phase splitter 50 utilized in conjunction with the flow shaping line 17 shown. FIG. 4 also illustrates an optional heater 68 utilized in conjunction with flow shaping line 17 . Heater 68 is particularly useful when the flow 12 includes certain liquid components which are desirably removed as a gas utilizing system 10 . For example, certain liquid hydrocarbons, such as methane or gasses that might move from liquid to gas at different flash or boiling temperatures, may be present in a flow 12 recovered from a wellbore (see FIG. 11 ). Rather than recover the hydrocarbons as liquids, it may be desirable to heat the flow 12 using heater 68 to a temperature where the hydrocarbons convert to gas 22 , after which the hydrocarbon gas 22 can be removed through outlet port 28 and separator 38 .
FIG. 5 illustrates the system 10 shown in FIG. 4 , but with all of the loop diameters D approximately the same dimension. In the embodiment of FIG. 5 , residence time may be maintained while the adjustable mechanism 58 in phase splitter 50 is adjusted based on one of the sensors 34 , 60 .
FIG. 6 a illustrates the multi-loop system 10 shown in FIG. 4 , but with two sets of loops. In this case, a first flow shaping line 17 a and a second flow shaping line 17 b are illustrated. Flow shaping lines 17 a , 17 b each have multiple loops L, which loops L may have substantially the same diameter D or successively increasing or decreasing diameters D. The flow can be divided and processed in parallel so that portions of the flow stream are simultaneously processed as described above, after which, the liquid from each set of loops can be recombined and directed towards outlet 72 . Multiple sets of loops arranged in parallel are particularly useful in cases of large flow volume
The system 10 of FIG. 6 b is the same as that of FIG. 6 a , but the loops L have substantially the same diameter D. The system of FIG. 6 b may also be used in conjunction with a heater 68 , cut sensors and adjustable cut mechanism 30 b as described herein.
With reference to FIG. 7 , system 10 includes two sets of loops arranged in series. In this case, a first flow shaping line 17 c and a second flow shaping line 17 d are illustrated. Flow shaping lines 17 c , 17 d each have multiple loops L, which loops L may have substantially the same diameter D or successively increasing or decreasing diameters D. In the illustrated embodiment, in each set of loops, the loops L have a gradually decreasing diameter along the curvilinear flow path 16 . A heater 68 may be disposed to convert part of the flow 12 to a gaseous phase. Outlet port 28 to line 33 leading to separator 38 is positioned along the flow shaping line 17 c at a point where it is expected a substantial amount of phase separation to have occurred after passing through at least a portion of the curvilinear flow path 176 . A sensor 34 is positioned in order to measure a property of the flow 12 . Sensor 34 is spaced apart along flow shaping line 17 c a sufficient distance to allow the flow 12 to have a residence time in the loops prior to reaching outlet port 28 positioned on inner wall 24 , thereby permitting an adjustable separation mechanism, such as 30 b shown in FIG. 2 , to be adjusted accordingly. First flow shaping line 17 c is intended to remove a large portion of the gas 22 that comprises fluid flow 12 . Thereafter, the liquid 18 passes through line 43 and into the second flow shaping line 17 d to remove remaining gas that may be within the flow exiting the first flow shaping line 17 c . Again, a sensor 34 may be utilized in conjunction with an adjustable separation mechanism adjacent outlet port 28 of second flow shaping line 17 d.
In one configuration of the system 10 shown in FIG. 7 , flow shaping lines 17 d operates as describe in FIG. 2 , passing a liquid comprised of substantially first and second liquid components 18 a , 18 b into phase splitter 50 . A sensor 60 may be disposed along flow shaping line 17 d to control an adjustment mechanism 58 disposed within phase splitter 50 .
Multiple sets of loops are particularly useful in cases of large flow volume. The flow can be divided and processed in parallel so that portions of the flow stream are simultaneously processed as described above, after which, the liquid from each set of loops can be recombined and directed towards outlet 72 .
Turning to FIG. 8 , another embodiment of a flow shaping line 17 is illustrated. In this embodiment, flow shaping line 17 is shown in cross section and includes a channel 74 formed along the inner wall 24 of at least a portion of the curvilinear flow path 16 . Channel 74 may be utilized in any configuration of a flow shaping line 17 having a curvilinear portion, including flow shaping line formed in both single loop and multiple loop arrangements. It has been found that such systems 10 having a channel 74 are particularly effective in multi-phase flow regimes with a high gas to liquid content. In other words, flow 12 is comprised primarily of gas 22 , with a relative low amount of liquid 18 suspended therein. As flow 12 follows the curvilinear shape of flow shaping line 17 , the liquid 18 will become trapped within channel 74 and can be drained off through an outlet port 28 disposed along channel 74 . Thereafter, the separated liquid may be introduced into a second curvilinear flow shaping line 17 without a channel xx to permit separation of gas from liquid as depicted and discussed in the foregoing embodiments and illustrations.
FIG. 9 illustrates one embodiment of an adjustable separation mechanism 58 for use in phase splitter 50 . Adjustable separation mechanism 58 is a ball valve 76 having a ball 78 rotatably mounted in a ball seat 80 carried within a phase splitter housing 82 . Ball 78 includes a first passageway 84 having an inlet 86 and an outlet 88 , as well as a second passageway 90 having an inlet 92 and an outlet 94 . Passageways 84 and 90 are formed in ball 78 so that inlets 86 , 92 are adjacent one another, while outlets 88 , 94 are spaced apart from one another. In one embodiment, passageways 84 , 90 converge at inlets 86 , 92 so that a portion of ball 78 defining passageways 84 , 90 forms an edge 96 . As previously described, phase splitter 50 includes a liquid inlet 52 , a first outlet 54 and a second outlet 56 . Ball valve 76 is disposed in seat 80 so that the inlets 86 , 92 are adjacent fluid inlet 52 , first ball outlet 88 is in fluid communication with first outlet 54 and second ball outlet 94 is in fluid communication with outlet 56 . In a preferred embodiment, edge 96 is positioned adjacent inlet 52 . Rotation of ball 78 thereby adjusts the position of edge 96 in liquid stream 18 as liquid stream 18 flows across edge 96 . In this way, valve 76 can be adjusted to alter the cut from liquid steam 18 such that a portion of the liquid 18 a flows through first passageway 84 and a portion of the liquid 18 b flows through the second passageway 90 . Persons of ordinary skill in the art will understand that passageways 84 , 90 , and their respective inlets 86 , 92 may be sized so that valve 76 may also be adjusted to divert all of liquid 18 flowing though inlet 52 into either first or second passageway 84 , 90 , as desired.
With reference to FIG. 10 , a variable position gas control valve 98 is placed on the gas outlet 39 side of the two-phase separation vessel 38 . The liquid outlet 41 is unregulated and allowed to drain. As gas is allowed to escape the level increases in the vessel and when gas is not allowed to escape the level decreases. The incoming flow 40 is controlled and maintained at a specific level in separator 38 in order to stabilize the pressure therein so that liquid full flow bypass can be maintained without peeks or fluctuations in flow rate.
As described above, one application for the invention is to protect against “kicks,” such as in subsea applications, by circulating out hydrocarbon gas at the seabed floor before the gas is able to rise up to a drilling rig. Referring to FIG. 11 , in an exemplary embodiment, illustrated is a conventional sub-sea blow out preventer 150 located on the seafloor 152 . A marine riser 154 extends from the blow out preventer 150 and within the riser is a drillpipe 156 . One embodiment of the separation apparatus 110 is positioned along drillpipe 156 , preferably adjacent the blow out preventer 150 . In normal drilling operations, drilling fluid 158 is pumped down the drillpipe 156 from the drilling rig 157 and returns to the drilling rig 157 via annulus 160 formed between the drillpipe 156 and the riser 154 . If a “kick” is detected, such as by cut or similar sensors described herein, inlet annulus valve 162 is activated, diverting returning drilling fluid 158 from annulus 160 into the flow shaping line 117 . Flow shaping line may have one or multiple sets of coils. In the case of a single set of coils, flow shaping line is preferably arranged so that successive loops L along the line 117 having a decreasing diameter. In the case of multiple sets of coils, the flow shaping lines 117 may be arranged in parallel. Natural gas entrained in drilling fluid 158 from the “kick” is then separated from the drilling fluid 158 by the separation apparatus 110 as described above. Specifically, gas will exit flow shaping line 117 into a separator 138 . The natural gas then exits the gas-liquid separator 138 at the gas exit 139 and may flow up riser 166 to the drilling rig where it may be safely handled, for example, sent to a flare boom of the drilling rig 157 , or compressed and re-distributed (also not shown).
Following separation of natural gas from the recovered drilling fluid 158 by separation apparatus 110 , the drilling fluid 158 is re-introduced into the annulus 160 at an exit annulus valve 168 . In comparison with the usual procedure of handling a kick, the use of an embodiment of this invention allows for full flow or circulation of the drilling fluid without having to choke down the flow or operate the blow out preventer valves.
In another embodiment, the inlet annulus valves 162 or exit annulus valves 168 can be eliminated, bypassed or operated so that the upward flowing drilling fluid 158 continually flows through the separation apparatus 110 . Compared to the usual procedure on a drilling rig when there is a kick of choking the flow of the drilling fluid and being able to only send a portion of the flow to the mud-gas separator located on the drilling rig, an embodiment of the present invention allows the full flow of the drilling fluid to be handled by the separation apparatus 110 and the separation safely takes place near the seafloor.
In one embodiment, flow shaping line 117 may comprise multiple loops of decreasing diameter as described above and illustrated in FIG. 11 . In other embodiments, flow shaping line 117 may comprise a single loop or multiple loops of substantially the same diameter, but utilized in conjunction with a heater 68 to convert certain hydrocarbons to gas and/or a sensor 34 utilized in conjunction with an adjustable cut mechanism 30 b (see FIG. 2 ), such as a foil, weir plate or valve.
In another embodiment illustrated in FIG. 11 , a separation apparatus 210 having a flow shaping line 211 is utilized in conjunction with drilling and a hydrocarbon recovery system near the ground or water surface 212 . A fluid flow (such as fluid flow 12 in FIG. 2 ) from a wellbore 216 is directed into flow shaping line 211 positioned adjacent a drilling rig 157 . In normal drilling operations, drilling fluid 158 is pumped down a drillpipe 156 from the drilling rig 157 and returns to the drilling rig 157 via annulus 160 formed between the drillpipe 156 and a pipe 154 , such as a riser in the case of marine drilling operations or a well casing in the case of land drilling operations. The recovered drilling fluid 158 from annulus 160 is directed into the flow shaping line 211 . Preferably, drilling mud and cuttings are first removed from the flow 214 using various systems 215 known in the industry before introduction into flow shaping line 211 . Natural gas entrained in drilling fluid 158 is then separated from the drilling fluid 158 by the separation apparatus 210 as described above. Specifically, gas will exit flow shaping line 211 into a separator 238 . The natural gas 164 exits the gas-liquid separator 238 at the gas exit 239 .
In one embodiment, flow shaping line 211 may comprise multiple loops of decreasing diameter as described above and illustrated in FIG. 4 . In other embodiments, flow shaping line 211 may comprise a single loop or multiple loops of substantially the same diameter, but utilized in conjunction with a heater 68 to convert certain hydrocarbons to gas and/or a sensor 34 utilized in conjunction with an adjustable cut mechanism, such as a foil, weir plate or valve. Moreover, separation apparatus 210 may include a phase splitter 220 in fluid communication with line 211 and disposed to separate liquid components as described above.
In another embodiment illustrated in FIG. 12 , a multi-phase flow separation apparatus 310 can be utilized in bunkering operations to supply ships with fuel. Bunker fuel generally refers to any type of fuel oil used aboard ships. Bunker fuels are delivered to commercial ships via bunker barges, which often hold the bunker fuel in large tanks 312 . The practice of delivering bunker fuels is commonly referred to as “bunkering”, as such bunker barges can also be known as bunkering barges. The bunker fuel is typically pumped from the barge's tanks 312 to the tanks 314 on commercial ships. At times, bunker fuels may be transferred between bunker barges. In any event, the pumping of fuel in bunkering operations, especially as the vessels containing the fuel are emptied, larger amounts of air tend to be drawn in and pumped with the fuel, rendering pumping difficult and resulting in inaccurate measurements of fuel. Thus, in certain embodiments, a system 310 is disposed in line between a first fuel storage vessel 312 and the vessel to which the fuel is being pumped, namely a second fuel storage vessel 314 . While system 310 may be of many different configurations as described herein, in certain preferred embodiments, system 310 includes, as shown in FIG. 12 , a curvilinear flow path 316 in a flow shaping line 317 . Flow shaping line 317 includes a plurality of successive loops L of substantially the same diameter, each loop L being substantially horizontally disposed, thereby forming a “stack” of loops L. It has been found that in the case of loops L disposed substantially in the horizontal, the diameters of the loops, i.e., the coil sizes, do not need to be successively descending from the first end 364 of flow shaping line 317 to the second end 366 as is desirable in vertical orientation of the loops. Thus, fuel is removed from the first vessel 312 , passed through system 310 and then directed to the second vessel 314 . The fuel entering the first end 364 of flow shaping line 317 may have a large proportion of air included with the liquid fuel. The liquid fuel exiting the second end 366 of flow shaping line 317 has been substantially scrubbed of the entrained air.
Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
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A multi-phase separation apparatus shapes fluid flow in a flow shaping line preferably shaped to have a plurality of loops with consecutively decreasing diameters. Shaping the two-phase flow drives the heavier, denser fluids to the outside wall of the flow shaping line and allows the lighter, less dense fluids such as gas to occupy the inner wall of the flow shaping line. With the gas positioned on the inner wall, an exit port on the inner wall permits a majority, if not all, of the gas, along with a minimal amount of liquid, to be diverted to a conventional gas-liquid separator at a flow rate much lower than the total flow rate within the flow shaping line. The remaining liquid flow in the flow shaping line is subsequently introduced into an adjustable phase splitter to separate different liquid components from one another.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of prior U.S. provisional application No. 60/280,684, filed Mar. 30, 2001.
BACKGROUND
The invention relates to an Internet security system. The growth of the Internet and high-traffic web sites that require high performance and high bandwidth networks have resulted in an increased number of so-called service providers, including Internet data centers, application service and security service providers. A service provider, including an Internet data center, provides network resources, one or more dedicated servers and, in some cases, physical space, to host services for a number of customers, usually for a fee. Conventionally, service providers must install and configure one or more dedicated servers to support each customer and will likely require complex networks to manage separate services for the service provider's customer base. In this environment, the customer typically has some administrative control of the servers and control of the content residing on the servers. An Internet data center typically provides the network, network access, hardware, software and infrastructure needed to power the service, including web site, managed security, and so on.
An exemplary view of the organization of a conventional Internet data center is shown in FIG. 1 . In the present example, the Internet data center ( 100 ) has a number of customers A, B, C, D. The Internet data center ( 100 ) shown in FIG. 1 is set up for four customers only, while in reality a data center may host hundreds or potentially thousands of users. Each customer has one or more dedicated servers ( 105 ), a dedicated firewall ( 110 ) and one or more switches ( 115 ) that are all connected and form a subnet ( 120 ) for that particular customer. The subnets ( 120 ) are coupled together in the core switch fabric ( 125 ), which in turn forms an interface to the Internet.
The conventional model for organizing an Internet data center requires that a separate firewall device be deployed every time a new customer joins the Internet data center, which may require network re-configuration, and be a labor intensive and costly task. In this environment, the staff at the Internet data center must separately configure, upgrade, manage and support each firewall device separately. The conventional way for organizing Internet data centers also requires a heavy need for physical rack space to accommodate the physical installation of separate firewall and other networking devices upon which the provider's services are hosted. As a result of the large amount of separate equipment, the wiring and related switching and routing infrastructure becomes complex. If a firewall fails, it will be costly to repair or replace and the down time the client experiences before his or her firewall has been repaired or replaced may be considerable. The down time can be reduced if redundant boxes are provided, but this solution leads in turn to increased cost, space, maintenance and wiring problems, and is therefore not a desirable solution.
SUMMARY
In general, in one aspect, this invention provides methods and apparatus, including computer program products, implementing and using techniques for processing data packets transferred over a network. The data processing system includes a firewall engine that can receive a set of firewall policies and apply the firewall policies to a data packet, an authentication engine that can receive a set of authentication policies and authenticate a data packet in accordance with the authentication policies, one or more virtual private networks that each have an associated destination address and policies and a controller that can detect an incoming data packet, examine the incoming data packet for a virtual private network destination address and identify the policies associated with the virtual private network destination. If the policies include firewall policies, then the controller can call the firewall engine and apply the set of firewall policies corresponding to the virtual private network destination to the data packet. If the policies include authentication policies, then the controller can call the authentication engine and apply the set of authentication policies corresponding to the virtual private network destination to the data packet. The controller can also route the data packet to the virtual private network containing the data packet's destination address.
Advantageous implementations can include one or more of the following features. The controller can route the data packet by reading a set of entries in a private routing table and outputting the data packet to its virtual private network destination address using a routing protocol associated with the packet's virtual private network destination address.
In general, in one aspect, this invention provides methods and apparatus, including computer program products, implementing and using techniques for processing a data packet in a packet forwarding device. A data packet is received and a virtual local area network destination is determined for the received data packet, including identifying a set of rules that are associated with the virtual local area network destination. The set of rules is applied to the data packet and if a virtual local area network destination has been determined for the received data packet, the data packet is output to its virtual local area network destination, using the result from the application of the rules. If a virtual local area network destination has not been determined for the received data packet, the data packet is dropped.
Advantageous implementations can include one or more of the following features. A traffic policy can be applied to the received data packet, the traffic policy being associated with the packet forwarding device and applied to all data packets processed by the packet forwarding device. Determining a virtual local area network destination can include extracting layer information from the data packet and using the extracted layer information to determine a virtual local area network destination for the data packet. The layer information can include layer 2 information, layer 3 information, layer 4 information and layer 7 information. Applying the rules to the data packet can include shaping the data packet based on the virtual local area network destination and discarding the data packet if no virtual local area network destination is determined. Shaping the data packet can include attaching a digital address tag to the data packet, the digital address tag identifying a virtual local area network destination. The digital address tag can be read and the data packet can be output using the digital address tag content.
Applying the rules to the data packet can include applying a set of rules selected from network address translation, mobile internet protocol, virtual internet protocol, user authentication and URL blocking. Applying the rules to the data packet can include applying a set of policies selected from incoming policies and outgoing policies for a virtual local area network destination. Entries from one or more of a global address book, a private address book, and a global service book can be received and applying the rules to the data packet can include using the retrieved entries.
Available resources for outputting the data packet to the virtual private network destination can be determined, wherein the resources are definable by a user. Outputting the data packet can include outputting the data packet to a determined virtual private network destination in accordance with the determined available resources. Applying the rules to the data packet can include applying a set of virtual tunneling rules for a virtual local area network destination, where the tunneling rules are selected from PPTP, L2TP and IPSec tunneling protocols. Outputting the data packet can include reading a set of entries in a private routing table and if a virtual local area network destination has been determined for the received data packet, outputting the data packet to its virtual local area network destination using a routing protocol for the packet virtual local area network destination. A set of rules configured by a user can be received.
In general, in one aspect, this invention provides methods and apparatus, including computer program products, implementing and using techniques for screening data packets transferred over a network. A connection to one or more virtual local area networks is established. A set of firewall configuration settings are associated with each of the one or more virtual local area networks. An incoming data packet is received. The incoming data packet is screened in accordance with a set of firewall configuration settings and the screened data packet is output to a particular virtual local area network among the one or more virtual local area networks, based on the result of the screening.
In general, in one aspect, this invention provides methods and apparatus, including computer program products, implementing and using techniques for transferring packets of data. One or more packet processing engines can receive an incoming packet of data, apply a global traffic policy to the incoming packet, classify the incoming packet including determining a virtual local area network destination, shape the incoming packet based on the virtual local area network destination and output the shaped packet.
Advantageous implementations can include one or more of the following features. One or more switches can be connected to the packet processing engine by a trunk cable to receive the shaped packet from the packet processing engine through the trunk cable, determine a destination device to which the shaped packet is to be routed and switch the shaped packet to a communication link that is connected to the destination device. The trunk cable can be a VLAN cable. A first packet processing engine of the one or more packet processing engines can be connected to a first switch of the one or more switches, and cross connected to at least a second switch of the one or more switches and a second packet processing engine of the one or more packet processing engines can be connected to the second switch of the one or more switches and cross connected to at least the first switch of the one or more switches.
Each of the first and second switches can connect to one or more communication links, each communication link representing a virtual local area network destination. A trunk cable can connect a switch and a packet processing engine. One or more virtual local area networks (VLANs) can be connected to the one or more switches via a communication link dedicated for the virtual local area network. Outputting the packet can include outputting the shaped packet to its virtual local area network destination through a destination port on the packet processing engine, the destination port connecting the packet processing engine via a communication link to a destination device.
One or more virtual local area networks (VLANs) can be connected to a destination port on the packet processing engine via a communication link dedicated for the virtual local area network. Each packet processing engine can perform one or more functions that are configurable for each virtual local area network.
In general, in one aspect, this invention provides methods and apparatus, including computer program products, implementing and using techniques for providing a security system including security system resources including firewall services and a controller that can partition the security system resources into a plurality of separate security domains. Each security domain can be configurable to enforce one or more policies relating to a specific subsystem, and to allocate security system resources to the one or more security domains.
Advantageous implementations can include one or more of the following features. The security system can allocate security system resources to a specific subsystem. The specific subsystem can be a computer network. The specific subsystem can be a device connected to a computer network. Each security domain can include a user interface for viewing and modifying a set of policies relating to a specific subsystem. The security system resources can include authentication services. The security system resources can include virtual private network (VPN) services. The security system resources can include traffic management services. The security system resources can include encryption services. The security system resources can include one or more of administrative tools, logging, counting, alarming and notification facilities, and resources for setting up additional subsystems.
A management device can provide a service domain, the service domain being configurable to enforce one or more policies for all security domains. The management device can include a user interface for viewing, adding and modifying any set of policies associated with any specific subsystem and the set of policies associated with the service domain. The service domain can include a global address book. Each set of security domain policies can include one or more policies for incoming data packets, policies for outgoing packets, policies for virtual tunneling, authentication policies, traffic regulating policies and firewall policies. The policies for virtual tunneling can be selected from the group consisting of PPTP, L2TP and IPSec tunneling protocols. One or more of the security domains can include a unique address book.
The invention can be implemented to realize one or more of the following advantages. A single security device can be used to manage security for multiple customers. Each customer has their own unique security domain with an address book and policies for management of content. Each domain is separately administrated. One customer's policies do not interfere with the other customers' policies. Additionally, attacks on one customer's domain will not have any influence on the functionality of other domains. To each customer, the firewall and any virtual private networks (VPNs) appear to be hosted on a discrete device, just like the conventional systems. For an Internet data center that employs the Internet security system in accordance with the invention, a number of benefits may result. Instead of upgrading and managing one device for each customer, a single device can be upgraded and managed for several customers. Less rack space will be required, since fewer devices are necessary, and as a consequence, the wiring scheme will be less complicated. The cost of deployment will be lower, the network complexity and requirements will be reduced, and higher performance throughput will be possible.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features and advantages of the invention will become apparent from the description, the drawings, and the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic view of a prior art security system configuration for an Internet data center.
FIG. 2 is a schematic view of an Internet security system in accordance with the invention.
FIG. 3 is a schematic view of an Internet security system in accordance with an alternative implementation of the invention.
FIG. 4 is a schematic view of an Internet security system in accordance with another alternative implementation of the invention.
FIG. 5 is a flowchart showing a data packet processing method in accordance with the invention.
FIG. 6 is a flowchart detailing one implementation of the packet classification step in FIG. 5 .
FIG. 7 is a flowchart detailing one implementation of the packet classification step in FIG. 5 .
FIG. 8 is a flowchart detailing a alternative implementation of the packet classification step in FIG. 5 .
FIG. 9 is a schematic block diagram showing a more detailed view of the security device in FIG. 3 .
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
An Internet security system in accordance with the invention provides a multi-customer, multi-domain architecture that allows service providers, such as Internet data centers, application infrastructure providers and metropolitan area network providers to manage the security needs of multiple customers through one centralized system. The inventive Internet security system also allows service provider and end user customers to create and manage separate security domains, each domain acting as a stand alone system and having its own set of policies. The inventive Internet security system accomplishes this through unique architecture and software features that can be referred to as Virtual Systems. The Internet security system will be described by way of example. Three different exemplary architectures will be described with reference to FIGS. 2–4 . After the architectural system description of each implementation, the data flow through the system will be described. Finally, the user interface and a number of customizable functions of the Internet security system will be presented.
Internet Security System Using Virtual Local Area Networks
As shown in FIG. 2 , the Internet security system ( 200 ) in accordance with one implementation of the invention includes a first 100/1000 router switch ( 205 ) that connects a firewall device ( 210 ) to the Internet ( 215 ). The firewall device ( 210 ) acts as a common firewall for all the customers, and can be separately configured to fit each customer's policies and security needs. How the separate configurations are done will be explained in further detail below. On the secure side of the firewall device ( 210 ) is a Virtual Local Area Network (VLAN) trunk ( 220 ) that carries all packets to a second 100/1000 switch ( 225 ). A VLAN is a Layer 2 multiplexing technique that allows several streams of data to share the same physical medium, such as a trunk cable, while enjoying total segregation. The second switch ( 225 ) directs the packets on private links to the different customers' servers ( 230 ) through a 10/100 switch ( 235 ) for each customer.
An incoming data packet from the Internet ( 215 ) first passes the router switch ( 205 ) and enters the firewall device ( 210 ). The firewall device ( 210 ) determines what VLAN the packet is intended for and attaches a VLAN tag to the packet. In one implementation, the tag that is used is a 802.1Q tag. The 802.1Q VLAN tag requires 12 bits in the Ethernet packet header to hold the tag, and is defined in the 802.3ac Ethernet frame format standard ratified in 1998. The 802.3ac Ethernet frame format standard is supported by most backbone switches fabricated since the ratification of the standard. There are two ways to attach a tag to a data packet; implicit tagging and explicit tagging. The implicit tagging method assigns a tag to untagged data packets, typically based on which port the data packet came from. The implicit tagging method allows traffic coming from devices not supporting VLAN tagging to be implicitly mapped into different VLANs. The explicit tagging method requires that each data packet be tagged with the VLAN to which the data packet belongs. The explicit tagging method allows traffic coming from VLAN-aware devices to explicitly signal VLAN membership.
The packet then continues on VLAN trunk ( 220 ) to the VLAN switch ( 225 ), where the tag attached to the packet by the firewall device ( 210 ) is read. Based on the VLAN tag, the packet is routed by the VLAN switch ( 225 ) to the appropriate switch ( 235 ) and server ( 230 ). The operation of the firewall device ( 210 ) will be described in more detail below.
Internet Security System Using Port-Based Virtual Local Area Networks
Another implementation of the invention is shown in FIG. 3 , which shows essentially the same architecture as shown for the Internet security system in FIG. 2 . The difference is that the firewall device ( 210 ) has been replaced with a firewall device ( 305 ) with port-based VLAN. From each port in the firewall with the port based VLAN, there is a private link ( 310 ) to each customer, switch ( 315 ) and server ( 320 ). The system ( 300 ) does not include the VLAN trunk or the second 100/1000 switch of the Internet security system implementation shown in FIG. 2 .
An incoming data packet from the Internet ( 325 ) first passes the router switch ( 330 ) and enters the firewall device ( 305 ). The firewall device ( 305 ) determines what system the packet is intended for. Instead of attaching a VLAN tag to the packet, the firewall device directs the packet to the proper dedicated port for the VLAN. The packet then continues on the selected private link ( 310 ) to the switch ( 315 ) and server ( 320 ) for the selected VLAN.
FIG. 9 shows a more detailed view of the Internet security system of FIG. 3 , and in particular of the firewall device ( 305 ). The firewall device ( 305 ) includes functionality not conventionally included in a firewall and can therefore be referred to more generally as a security system or a data processing system. The security system has a number of engines, such as a firewall engine ( 905 ), an authentication engine ( 910 ), and optionally other engines. A user interface ( 985 ) is also provided in the security system, which allows a user to set different policies for the different engines. The different engines communicate with each other through a bus ( 920 ). A user can set firewall policies for the firewall, such as incoming policies and outgoing policies for a virtual local area network destination, and authentication policies for the authentication engine, such as network address translation, mobile Internet protocol, virtual Internet protocol, user authentication and URL blocking.
When a packet comes in, a controller ( 915 ) detects the packet. The controller is connected to the bus ( 920 ) and can communicate with the engines. Also connected to the bus ( 920 ) is a set of virtual private networks ( 925 – 940 ), that each are connected to a network, optionally through one or more switches ( 315 ). The exemplary networks shown in FIG. 9 include two DMZs (Demilitarized Zones) ( 965 , 970 ), an extranet ( 975 ) and a general population net ( 980 ). Each of the virtual private networks (VPNs), has an associated destination address and policies. After the packet has been detected by the controller ( 915 ), the controller ( 915 ) examines the data packet for a virtual private network destination address and identifies the policies that are associated with the virtual private network destination. If the policies include firewall policies, the controller ( 915 ) calls the firewall engine ( 905 ), which applies the set of firewall policies corresponding to the virtual private network destination to the data packet. If the policies include authentication policies, the controller ( 915 ) calls the authentication engine ( 910 ), which applies the set of authentication policies corresponding to the virtual private network destination to the data packet. After the respective engine has applied the policies, the data packet is routed to the virtual private network corresponding to the data packet's destination address. How the incoming data packet is examined will be described in greater detail below.
The security system as a whole thus has a finite amount of security system resources, including firewall and authentication services. The controller partitions the security system resources into a number of separate security domains, each security domain being related to a private or public network. Each security domain is configurable to enforce one or more policies relating to a specific subsystem or network. The controller allocates security system resources to the one or more security domains based on the needs of the respective security domain, by calling the different engines, as described above. Instead of the static resource allocation in conventional Internet security systems with one security device or firewall per client, as was described in the background section above, the inventive Internet security system provides dynamic resource allocation on a as needed basis for the different virtual private networks and associated systems.
The security system resources can include a wide range of resources, such as authentication services, virtual private network (VPN) services, include traffic management services, encryption services, administrative tools, logging, counting, alarming and notification facilities, and resources for setting up additional subsystems.
Internet Security System Using Virtual Local Area Networks with High Availability
Yet another implementation of the invention is shown in FIG. 4 , which shows an Internet security system architecture ( 400 ) similar to that shown in FIG. 2 . However, in order to provide the ability to accommodate more traffic and to provide higher availability in the event of equipment failure, the system provides dual firewalls ( 405 , 410 ) and dual second switches ( 415 , 420 ). The first switches have been replaced with switch/routers ( 425 , 430 ) that can direct incoming traffic to either firewall ( 405 , 410 ). Each firewall is connected to both second switches ( 415 , 420 ) through VLAN trunks ( 435 ), and each of the second switches is connected to all the customer switches ( 440 ) by private links ( 445 ). The cross connection scheme ensures that an alternate route for data packages will be available, even in the event of component failure, and a high availability is thereby ensured.
An incoming data packet from the Internet arrives at one of the router switches ( 425 , 430 ). The router switch decides what firewall device ( 405 , 410 ) to send the packet to, based on which firewall device currently has most available capacity and sends the packet to that firewall device. Just like the above-described implementation shown in FIG. 2 , the firewall device ( 405 , 410 ) determines what VLAN the packet is intended for, and attaches a VLAN tag to the packet. The packet then continues on VLAN trunk ( 435 ) to the VLAN switch ( 415 , 420 ) with the most available capacity, where the tag attached to the packet by the firewall device ( 405 , 410 ) is read. Based on the VLAN tag, the packet is routed by the VLAN switch ( 415 , 420 ) through a private link ( 445 ) to the appropriate switch ( 440 ) and server ( 450 ).
Packet Classification and Context Partition
The following example describes a process for classifying and sending out an incoming packet to the appropriate virtual system using the firewall device in the Internet security system in accordance with the invention. As shown in FIG. 5 , a process ( 500 ) for classifying and sending out an incoming data packet begins with receiving a data packet ( 505 ). In the present example, the data packet is assumed to come from a trusted host. Data packets that are received from an untrusted host will be treated somewhat differently, which will be described below.
Once the data packet has been received, the layer 2 (L 2 ) information and the layer 3 (L 3 ) information is extracted from the packet ( 510 ). The L 2 information includes: Interface Number and VLAN ID. The L 3 information includes IP head or information.
After the L 2 and L 3 information has been extracted, one or more global traffic policies are applied to the packet ( 515 ). The global traffic policies apply to all virtual system domains in the Internet security system.
When the global traffic policies have been applied, the packet goes through a classification ( 520 ) to find a Virtual System Context. The virtual system context is an object containing all the configuration parameters for the virtual system to which the packet is destined. The packet classification is based a combination of the interface, VLAN ID and/or L 3 /L 4 (that is, TCP/UDP port) information. In a simple configuration, Interface and VLAN ID will be sufficient, while in a more complicated configuration, all the information listed above is necessary to locate the right context. The packet classification step is essential for the method and will be described in further detail below after the overall data packet processing procedure has been described.
The procedure then checks if a virtual system context has been found ( 525 ). If no virtual system context can be found, the packet is dropped and the event is logged ( 530 ). If a virtual system context has been found, the packet will be subjected to firewall/VPN/traffic shaping processing ( 535 ), in the same way as the packet would be processed on a stand-alone device. After the firewall/VPN/traffic shaping processing the procedure transforms the packet into an egress packet, and the L 2 information is encapsulated ( 540 ) before the packet is transmitted out through a designated interface port to the proper Virtual private network, which completes the procedure.
If the incoming packet comes from an untrusted interface, the processing is somewhat different than when the packet originates at a trusted interface. The different processing is necessary because an untrusted interface may be shared among several virtual systems. Therefore, the packet classification step ( 520 ) will, optionally, use more information, such as tunnel identifications for protocols such as IPSEC, L2TP. When a tunnel has been identified, the virtual system context can be identified, and the packet can pass to the Firewall/VPN/Traffic shaping step ( 535 ).
For non-tunnel traffic, a policy-based and session-based look-up table may be used to identify a virtual system context for the traffic from an untrusted interface. In the packet classification step ( 520 ), the packet will be subject to a global policy in order to identify if there is a session anywhere in the whole security system that matches with the packet. If such a session exists, the context point in the session record informs the security system about which virtual system context is the correct one. If there is no session match, but there is a policy that matches the packet, then that policy will point to the proper virtual system context for continued processing.
The classification step ( 520 ) described above determines to which virtual system the incoming data packet is destined. The classification step ( 520 ) will now be described in more detail with reference to FIGS. 6–8 that show in greater what happens to the data packet during the classification. Conceptually, the Internet security system in accordance with the invention can be viewed as processes in an operating system, the primary difference being that processes in an operating system are event driven, while the Internet security system is packet driven. When the Internet security system receives an incoming data packet, the system needs to classify the packet based on information contained in the packet and on the policies that have been configured for the system. When the packet has been classified, the virtual system context to which the packet belongs is found, and the packet is passed to the associated virtual system context for further processing. From the point of view of the virtual system, the packet appears to have originated in one of the virtual interfaces configured for the virtual system.
The classification of the incoming packet is made based on information from layer 2 (L 2 ), layer 3 (L 3 ), layer 4 (L 4 ) and layer 7 (L 7 ) information. The classification may be made based on one or more layers. For example, in a simple configuration, a virtual system using VLAN to separate different secure domains, the VLAN ID in the VLAN Ethernet packet is sufficient to classify the packet and identify the destination virtual system context. This is referred to as simple classification. An exemplary process for simple classification is shown in FIG. 6 , where the L 2 information is extracted ( 605 ), the virtual interface table is searched with the VLAN ID and the interface number ( 610 ). Based on the VLAN ID and the interface number, the process can determine whether a virtual system context has been found ( 615 ). If no virtual system context can be found, then the simple classification is not sufficient ( 620 ), and if a virtual system context can be found, then the simple classification is sufficient ( 625 ).
In an Internet security system with shared outside identity, a session database is used along with L 2 , L 3 and L 4 information to identify the correct virtual system. This is referred to as multi-layer classification. A process for multi-layer classification is shown in FIG. 7 , where the L 2 information ( 705 ), the L 3 information ( 710 ) and the L 4 information is extracted ( 715 ), before the session database is searched ( 720 ). Based on the L 2 , L 3 and L 4 information and the information in the session database, the process can determine whether a virtual system context has been found ( 725 ). If no virtual system context can be found, then the multi-layer classification is not sufficient ( 730 ), and if a virtual system context can be found, then the multi-layer classification is sufficient ( 735 ).
When complicated applications with dynamic port session (such as, FTP, RPC, H.323, and so on) are involved, a dynamic session database, along with L 2 , L 3 , L 4 , and L 7 (application layer) information are used to identify the virtual system context. This is referred to as L 7 classification. A process for L 7 classification is shown in FIG. 8 , where the L 2 ( 805 ), the L 3 ( 810 ), the L 4 ( 815 ) and the L 7 information is extracted ( 820 ) before the dynamic session database is searched ( 825 ). Based on the L 2 , L 3 , L 4 , and L 7 information and the dynamic session database, the process can determine whether a virtual system context has been found ( 830 ). If no virtual system context can be found, then the simple classification is not sufficient ( 835 ), and if a virtual system context can be found, then the simple classification is sufficient ( 840 ). Each of the simple, multi-layer or L 7 classification can be performed by itself, or the processes can be performed in series, going from the simple classification, through the multi-layer classification to the L 7 classification until the packet has been classified and a virtual system context has been identified.
The virtual systems are created through configuration of the Internet security system in real time or at start up with a saved configuration script. A system administrator creates virtual system context under a root privilege, and assigns certain attributes to the context. The system resources are now partitioned to support the new virtual system. A virtual system user can then log in to the system and will only see his or her virtual system, as if the user owned the whole system. A virtual system owner then can add, change and remove different attributes on the context. Once submitted, all attributes will be saved as configuration data for the Internet security system and be used to partition resources, change the global classification policy, and so on. How the Internet security system and individual virtual systems can be configured will be discussed in further detail below.
Configuring an Internet Security System
The description will now continue with an example showing how to configure an Internet security system in accordance with the invention, and showing three different examples of the user interfaces: one for a root level configuration, one where a root user creates a virtual system and adds configuration data, and one where a virtual system user logs in to a virtual system and changes configuration data.
First, a root user (that is, a system administrator for the whole Internet security system) with the user name “Netscreen” logs in to the system by entering the username and a password:
login: Netscreen password: ns1000->
The root user is now logged on and can access the root level interface configuration to view the different user interfaces that are present on the system. The command ‘get interface,’ for example, yields the following five interfaces, shown in Table 1 below.
TABLE 1
User interfaces present on the Internet Security System
Name
Stat
IP Address
Subnet Mask
MAC/VLAN/VSYS
Manage IP
Trust
Down
10.1.1.250
255.255.255.0
0010.dbf.1000
0.0.0.0
Trust/1
Down
11.1.1.250
255.255.255.0
Nat/trust.100(100)/
0.0.0.0
NULL
Untrust
Down
192.1.1.250
255.255.255.0
0010.dbf0.1001
Mgt
Up
0.0.0.0
0.0.0.0
0010.dbf0.1002
192.168.1.1
Ha
Down
0.0.0.0
0.0.0.0
0010.dbf0.1004
192.168.1.1
The root user can view the root level address entry configuration with the command ‘get address’ which yields the trusted, untrusted, and virtual addresses shown in Table 2 below:
TABLE 2
Trusted, Untrusted, and Virtual Addresses
Name
Address
Netmask
Flag
Comments
Trusted Individual Addresses:
Inside Any
0.0.0.0
0.0.0.0
02
All trusted addr.
T11net
11.1.1.0
255.255.255.0
00
Untrusted Individual addresses:
Outside Any
0.0.0.0
0.0.0.0
03
All Untrusted Addr
Dial-Up VPN
255.255.255.255
255.255.255.255
03
Dial-Up VPN Addr
u-199net
199.1.1.0
255.255.255.0
01
Virtual Individual Addresses:
All Virtual Ips
0.0.0.0
0.0.0.0
12
All Virtual Addr
The root user can view the Virtual Private Network configuration by typing the command ‘get vpn’ which yields the virtual private network configuration in Table 3 below. Here, there is only one VPN setting for the system.
TABLE 3
VPN systems for the Internet Security System
Name
Gateway
Local SPI
Remote SPI
Algorithm
Monitor
m-t11-u199
192.2.1.250
00001234
00004321
Esp:3des/null
Off
Total manual VPN: 1
To view the access policy configuration, the root user types the command ‘get policy’ which yields the three policies shown in Table 4 below for the root system.
TABLE 4
Policies for the root system in the Internet Security System
PID
Direction
Source
Destination
Service
Action
STLC
0
Outgoing
T-11net
u-199net
Any
Tunnel
—
1
Incoming
U-199net
t-11net
Any
Tunnel
—
2
Inside
Any
Outside
Any
Permit
—
The description will now continue with explaining how the root user can create a new virtual system named “marketing” and configure that system. The root user first adds the virtual system “marketing” to the Internet security system.
ns1000->set vsys marketing
The root user then adds configuration data to the newly created system “marketing” by first adding two virtual interfaces for the “marketing” system. Note how the prompt has changed to indicate that the root user is working in the “marketing” system.
ns1000(marketing)->set interface trust/200 ip 20.1.1.250 255.255.255.0 tag 200
ns1000(marketing)->set interface untrust/200 ip 193.1.1.250 255.255.255.0 tag 200
The next configuration to update is to add a virtual system private address entry to the “marketing” system.
ns1000(marketing)->set address trust t-20net 20.1.1.64 255.255.255.128
The root user then adds a MIP attribute to the private virtual interface, as well as two incoming/outgoing policies.
ns1000(marketing)->set interface untrust/200 mip 193.1.1.241 host 20.1.1.40
ns1000(marketing)->set policy incoming out-any mip(193.1.1.241) http permit
ns1000(marketing)->set policy outgoing t-20net out-any any permit auth
Next, the root user can verify the interface configuration settings by typing the command ‘get interface’. As shown above, the ‘get interface’ command yields the virtual interfaces for the current system. Since the current system is the “marketing” system, the root user will only see two virtual interfaces crated above, as shown in Table 5 below.
TABLE 5
Virtual interfaces for the “marketing” virtual system
Name
Stat
IP Address
Subnet Mask
MAC/VLAN/VSYS
Manage IP
Trust/200
Down
20.1.1.250
255.255.255.0
Nat/trust.200(200)/marketing
Trust/200
Down
193.1.1.250
255.255.255.0
Route/untrust.200(200)/
marketing
As described above, the root user can see the virtual system address configuration for the “marketing” system by typing the command ‘get address,’ which yields the address entries shown in Table 6 below.
TABLE 6
Address entries for the “marketing” system
Name
Address
Netmask
Flag
Comments
Trusted Individual Addresses:
Inside Any
0.0.0.0
0.0.0.0
02
All trusted addresses
T-20net
20.1.1.64
255.255.255.128
00
Untrusted Individual addresses:
Outside Any
0.0.0.0
0.0.0.0
03
All Untrusted Addresses
Dial-Up VPN
255.255.255.255
255.255.255.255
03
Dial-Up VPN Addresses
Virtual Individual Addresses:
All Virtual Ips
0.0.0.0
0.0.0.0
12
All Virtual Addresses
MIP
193.1.1.241
255.255.255.255
10
Untrust/200
The user can now retrieve the policies for the “marketing” system by typing the command ‘get policy’ at the prompt. The get policy command yields the following two policies for the “marketing” system, shown in Table 7 below.
TABLE 7
Policies for the “marketing” system
PID
Direction
Source
Destination
Service
Action
STLC
0
Incoming
Outside
MIP
HTTP
Permit
—
Any
(193.1.1.124)
1
Outgoing
t-20net
Outside Any
Any
Permit-
—
Auth
The configuration file for the “marketing” system virtual system can be obtained by typing ‘get config’ which yields:
Total Config size 1503: set vsys “marketing” set vsys-id 1 set auth type 0 set auth timeout 10 set admin name “vsys_marketing” set admin password nIxrDlr7BzZBcq/LyshENtLt9sLGFn set interface trust/200 ip 20.1.1.250 255.255.255.0 tag 200 set interface untrust/200 ip 193.1.1.250 255.255.255.0 tag 200 set interface untrust/200 mip 193.1.1.241 host 20.1.1.40 netmask 255.255.255.255 set address trust “t-20net” 20.1.1.64 255.255.255.128 set policy id 0 incoming “Outside Any” “MIP(193.1.1.241)” “HTTP” Permit set policy id 1 outgoing “t-20net” “Outside Any” “ANY” Permit Auth exit
The root user has now created a virtual system, configured the system, and verified that all the settings are correct. He or she then exits the marketing system, saves the new configuration and the prompt returns to the root level.
ns1000(marketing)->exit
Configuration modified, save? [y]/n y
Save System Configuration . . . Done
ns1000>
The current Internet security system settings can now be viewed by the root user by typing ‘get vsys’, which yields the settings shown in Table 8 below. As can be seen the Internet security system now has a marketing system and a sales system. The marketing system has one sub-interface, while the sales system has a trusted and an untrusted interface.
TABLE 8
Internet security system settings
Name
ID
Sub-interface
VLAN
IP/Netmask
Marketing
1
Trust/200
Trust.200
20.1.1.250/255.255.255.0
Sales
2
Trust/300
Trust.300
30.1.1.250/255.255.255.0
Untrust/200
Untrust.200
193.1.1.250/255.255.255.0
The description will now continue with showing what a user of a virtual system, a “marketing” system, sees and the operations he or she can perform when he logs in to the system. The user logs in with his username and password:
login: vsys_marketing password: ns1000(marketing)->
To change the policy configuration, the user types ‘get policy’ which yields the two policies shown in Table 7 above. Now, the user can remove the first policy with the command ‘unset policy 1’ and add a new policy to the “marketing” system by typing
ns1000(marketing)->set policy outgoing in-any out-any any permit auth
The new policy configuration can be shown by retyping the ‘get policy’ command, which yields the policies shown in Table 9 below.
TABLE 9
Modified policies for the “marketing” system
PID
Direction
Source
Destination
Service
Action
STLC
0
Incoming
Outside
MIP
HTTP
Permit
—
Any
(193.1.1.124)
2
Outgoing
Inside
Outside Any
Any
Permit-
—
Any
Auth
The user can then exit the “marketing” system and save the modified policies in the same way as the root user exited:
ns1000(marketing)->exit Configuration modified, save? [y]/n y Save System Configuration . . . Done
The above examples only showed how to change a few policies and components. In the Internet security system in accordance with the invention, the following components can be independently configured in a similar way to the above example:
Firewall—The firewall device can be configured for each user to include one or more of the following mechanisms: NAT (Network Address Translation), MIP/VIP (Mapped IP, Virtual IP), User authentication, URL Blocking.
Policy—A private policy set can be configured that is applied to traffic for a particular customer. The private policy can include both incoming and outgoing policies. The policies can use entries from a global address book, a defined private address book, and a global service book.
Traffic management—Each virtual interface can be given a specific bandwidth.
Administration and management—Various functions can be configured for administration purposes, such as administrator login, mail alert, syslog, counters, logs and alarms.
Virtual LAN—The Virtual LAN can be defined on virtual interfaces within the Internet security system. Once the virtual LAN has been defined, the received VLAN traffic will be directed to the indicated virtual interface and traffic destined to the indicated virtual interface will be properly tagged with a VLAN ID.
VPN—Combined with private policies, the VPN provides secure tunneling for selected traffic going through the Internet security system. The tunneling can be PPTP, L2TP and IPSec.
Routing—Each system may define a private routing table and routing protocol.
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. Accordingly, other embodiments are within the scope of the following claims.
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Methods and apparatus, including computer program products, implementing and using techniques for processing a data packet in a packet forwarding device. A data packet is received. A virtual local area network destination is determined for the received data packet, and a set of rules associated with the virtual local area network destination is identified. The rules are applied to the data packet. If a virtual local area network destination has been determined for the received data packet, the data packet is output to the destination, using the result from the application of the rules. If no destination has been determined, the data packet is dropped. A security system for partitioning security system resources into a plurality of separate security domains that are configurable to enforce one or more policies and to allocate security system resources to the one or more security domains, is also described.
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