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This application claims priority on U.S. Provisional Patent Application No. 60/222,487, filed Aug. 2, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to ion mobility spectrometers, and particularly to the method of generating ions and the sampling of the ionic population at different intervals as the ion molecule reactions proceed to equilibrium.
2. Description of the Related Art
Ion mobility spectrometers have been used for many years to determine whether molecules of interest are present in a stream of gas. The prior art ion mobility spectrometers function by acquiring a sample that is to be tested for the presence of the molecules of interest. Some prior art ion mobility spectrometers acquire the sample by wiping a woven or non-woven fabric trap across a surface that is to be tested for molecules of interest. Other prior art ion mobility spectrometers create a stream of gas adjacent the surface to be tested for the molecules of interest or rely upon an existing stream of gas. The sample is transported on a stream of inert gas to an ionization chamber. The prior art ion mobility spectrometer exposes the sample to a radio active material in the ionization chamber. The radio active material, such as nickel 63 or tritium bombards the sample stream with β-particles and creates ions.
The prior art ion mobility spectrometer further includes a drift chamber in proximity to the ionization chamber. The drift chamber is characterized by a plurality of field-defining electrodes and a collector electrode at the end of the drift chamber opposite the ionization chamber. Ions created in the ionization chamber are permitted to drift through the drift chamber and toward the collector electrode. The collector electrode detects and analyzes the spectra of the collected ions and provides an appropriate indication if molecules of interest are detected.
Ion mobility spectrometers have many applications, including security applications where the ion mobility spectrometer is used to search for and identify explosives, narcotics and other contraband. Examples of ion mobility spectrometers are shown in U.S. Pat. No. 3,699,333 and U.S. Pat. No. 5,027,643.
Improvements to the above-described early ion mobility spectrometer have been developed by Ion Track Instruments, Inc. and are referred to as ion trap mobility spectrometers. The ion trap mobility spectrometer provides greater sensitivity and reliability over the above-described ion mobility spectrometer. An example of an ion trap mobility spectrometer is described in U.S. Pat. No. 5,200,614 which issued to Anthony Jenkins. This prior art ion trap mobility spectrometer achieves improved operation by increasing ionization efficiency in the reactor and ion transport efficiency from the reactor to the collector electrode. More particularly, the ionization chamber of the ion trap mobility spectrometer is a field-free region where the ion population of both electrons and positive ions is allowed to build up by the action of the β-particles on the carrier gas. The high density of ions produces a very high probability of ionization of the molecules of interest, and hence an extremely high ionization efficiency.
U.S. Pat. No. 5,491,337 shows still further improvements to ion trap mobility spectrometers. More particularly, U.S. Pat. No. 5,491,337 discloses an ion trap mobility spectrometer with enhanced efficiency to detect the presence of alkaloids, such as narcotics.
Despite the operational efficiencies described in the above-referenced patents, there is a demand for still further improvements that enable cost reductions while increasing the resolution or selectivity of the spectrometer. There are also regulatory barriers to using radioactive material in some countries which prevents the use of portable applications of equipment containing a radioactive source.
Recent attempts to provide an electronic means of ionization have been described in U.K. Patent Appl. No. 98164452. This does not however provide for ionic reactions to occur in zero field conditions or to probe these reactions as they proceed to equilibrium. Subsequently the method is both less sensitive and less selective than that described herein.
SUMMARY OF THE INVENTION
The subject invention is directed to an ion trap mobility spectrometer that replaces the radioactive ionization source with a source of ions produced by high voltage electronic pulses. Ions are formed periodically in a reaction chamber and are allowed to maximize their population and thermalize in a field-free environment and then react with molecular species in the gas phase in the reaction chamber. After a short time, the ions are pulsed into the drift section of an ion trap mobility spectrometer, such as the drift section of the ion trap mobility spectrometer disclosed in U.S. Pat. No. 5,200,614. The reaction period may be varied to sample the ion population at different intervals. This enables the ion-molecule reactions to be monitored as the ion population approaches equilibrium. Results then can be analyzed to determine differences between reacting species because the molecular ion population varies at different time points approaching equilibrium. Thus, there is an improved identification of targets.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic cross-sectional view of an ion trap mobility spectrometer in accordance with the subject invention.
FIG. 2 is a schematic diagram of the circuitry for driving the electrodes of the ITMS shown in FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An ion trap mobility spectrometer (ITMS) in accordance with the subject invention is identified generally by the numeral 10 in the FIG. 1 . The ITMS 10 includes a cylindrical detector 12 having a gas inlet 14 at one end for receiving sample air of interest. The sample air of interest may be transported by a carrier gas.
This carrier typically is a clean and dry air that contains a small concentration of a dopant material, such as ammonia, nicotinamide or other such dopant, as disclosed in U.S. Pat. No. 5,491,337. Vapor samples from target materials are carried into the detector 10 on this gas stream from a suitable inlet system, such as the system described in U.S. Pat. No. 5,491,337.
Gas flow from the inlet 14 enters a reaction chamber 16 . More particularly, the reaction chamber 16 is a hollow metallic cylindrical cup 18 with the inlet 14 at one end. Two pin electrodes 20 and 22 protrude radially into the reaction chamber. The pin electrodes 20 , 22 are insulated to avoid discharge from places other than the radially inner points of each electrodes 20 , 22 . A grid electrode E 1 is provided at the opposite end of the reaction chamber 16 from the inlet 14 . The grid electrode E 1 normally is maintained at the same potential as the inlet end and the walls of the reaction chamber 16 . The creation of ions within the reaction chamber 16 will be described in greater detail below. The carrier gas passes through the reaction chamber 16 , exhausts around the metallic cylindrical cup 18 and exits the detector through the gas outlet 24 .
A drift section 26 is defined in the detector 10 downstream from the grid electrode E 1 . The drift section 26 comprises a plurality of annular electrodes E 2 -E N . Clean drift gas is arranged to flow down the detector 10 through the drift region 26 in the direction indicated by the arrows D in the FIG. 1 . The drift gas joins the carrier gas at the point at which the carrier gas leaves the reactor chamber 16 , and both the drift gas and the carrier gas are exhausted from the detector through the outlet 24 .
Most of the time, the electrical potentials on the metallic cylindrical cup 18 , both pins 20 , 22 and the grid E 1 are identical, thus defining the reaction chamber 16 as a field-free space. Periodically, however, a high voltage pulse is applied across the two pin electrodes 20 , 22 . Thus, the carrier gas is ionized by positive and negative corona discharge within the area of the reaction chamber 16 between the two pin electrodes 20 . In a negative DC corona, electrons are given off by the cathode pins 20 and are accelerated in the very high field adjacent the point of the pin 20 . Secondary ions thus are formed by bombardment of the carrier gas molecules. Mostly nitrogen positive ions and further electrons are produced in this secondary ionization process. The positive ions are attracted back into the cathode pin 20 where they cause further electrons to be emitted, thus maintaining the discharge. The electrons, meanwhile, move to a region of lower field strength and at some distance from the pin 20 . These electrons cease to cause further ionization of the carrier gas. Additionally, the electrons travel across the chamber toward the anode 22 . These electrons are well above thermal energies, and thus very few materials will interact to form negative ions. One notable exception, however, is oxygen. The oxygen will capture hypothermal electrons, thereby forming negative oxygen ions.
A major disadvantage of a simple corona as the potential source of ions for an ion mobility spectrometer is that charge transfer processes are inhibited at high energy. Another disadvantage is that fewer positive ions are available for ionic interactions, because they exist largely in the tiny volume surrounding the tip of the cathode 20 . However, the detector 10 described above and shown in the FIG. 1 provides almost equal numbers of positive ions and negative ions. The ions in this quasi-neutral plasma are allowed to interact at thermal energies, thus achieving all of the advantages of the ion trap mobility spectrometer described in U.S. Pat. No. 5,200,614. This is achieved by short high voltage electrical pulses of high frequency applied across the two electrodes 20 and 22 . The frequency typically is above 1 MHz so that the field collapses very rapidly before many electrons or positive ions can be collected at the relevant electrodes 20 and 22 . The plasma between the pins builds up during the pulse. After the pulse is switched off, the ions rapidly thermalize and react with molecular species present in the reaction chamber 16 . The charge transfer processes all proceed toward the formation of molecular ions that have the highest charge affinity. Depending on the molecular concentrations, charge may be transferred from one molecule species to another of higher affinity. U.S. Pat. No. 5,494,337 described one way of modifying this process using a dopant vapor (e.g., ammonia or nicotimamide), which has intermediate charge affinity between many interfering compounds and the target compounds of interest. The dopant vapor attracts and maintains the charge in the presence of interference molecules with weak charge affinity. However, the dopant vapor transfers the charge to the target molecule when they become present in the reaction chamber 16 . This reduces the number of different types of ions that are present, which in turn reduces the occurrence of false positive identifications by the detector 10 .
The discharge pulse in the detector 10 shown in the FIG. 1 is left on only for a sufficient time to generate enough charge to ensure efficient ionization of the target molecules. Typically the duration of the discharge pulse will be a few hundred microseconds, which is faster than the ions travel to the relevant electrode. Frequencies of 1 MHz or higher are preferred to achieve the required decay of the pin voltages.
After the discharge is switched off, approximately equal concentrations of positive and negative charges ensure that little or no space charge is generated within the reactor, thus maintaining a field-free space. This, in turn, allows all charges to reach thermal equilibrium quickly (<1 ms) at which point optimum charge transfer processes are encouraged. Molecules with the highest charge affinity ultimately will capture the charge from all other ionic species. If these high affinity molecules are present in the reaction chamber 16 only at parts per trillion concentrations, then only one interaction in 10 12 will cause charge to be transferred from any particular lower affinity ion to the target molecules. At atmospheric pressures and the temperature of the detector 10 , molecules typically interact (collide) at frequencies of about 10 8 per second. Ion concentrations in the reaction chamber 16 are generated which ensure that equilibrium ionization is achieved within a few milliseconds. Before this point is reached, many ionic species may be observed which may be associated with the target material. For example, a sample of cocaine vapor introduced into the detector from sampling a suspicious parcel may contain drug cutting compounds and other alkaloids. These may exist at higher concentration, but the positive charge affinity of cocaine is so high that at equilibrium, all of the charge resides on the cocaine ions, and the cutting compounds and other alkaloids will not be detected. Similarly, in the negative ion mode, mixtures of explosives may not be identified completely, since the stronger electronegative species will predominate. Before the end point equilibrium is reached, however, the lower charge affinity compounds will be ionized and can be detected. In the present arrangement, plasmagrams are obtained at differing time intervals after injecting the ionic charge into the reaction chamber.
The above-described method for sampling the ionic populations at different times after the discharge pulse is switched off allows non-equilibrium ionization to be observed and used as a further criteria for differentiating molecular species. Variation of the delay between the discharge pulse and the sampling of the ions in the reaction chamber 16 allows charge transfer processes to be studied and used to identify target materials more accurately. This is achieved by controlling and varying the time between the discharge pulse and the application of a high electric field across the reaction chamber 16 from the metallic cylindrical cup 18 to the grid E 1 . This high field is maintained across the reactor for just a sufficient time that most of the ions are expelled through the electrode E 1 into the drift section of the detector, in the same way as described in U.S. Pat. No. 5,200,614. The ions travel through the drift section 26 under the influence of electric fields defined by annular electrodes E 2 , E 3 . . . and E N . The ions pass through the guard grid 28 and are collected at the collector electrode 30 . The different ionic species travel down the drift section 26 to different speeds, which depend on molecular size and shape. Each ionic species travels in a swarm and arrives at the collector electrode 30 in a gaussian-shaped concentration profile. This in turn produces a peak of current at the signal output. The signal is amplified and the drift time measured to provide identification of the ion swarm.
The dual opposing corona discharge points or pin electrodes 20 and 22 within the reaction chamber 16 of the ITMS 10 are driven with high voltage from two paths as shown in FIG. 2 . For most of the time, the High Voltage Power Supply 32 , HV Switch Circuit 34 and HV Regulator 36 operate to keep the pin electrodes 20 and 22 at the same high voltage (e.g., 1000 volts) as the rest of the walls of the reaction chamber 16 and first grid electrode, E 1 . This is achieved via the high-value resistors R 1 and R 2 . The HV Switch Circuit is arranged as in the prior art ITMS, to occasionally provide a kick out pulse of higher voltage so that ions are driven from the chamber through the first grid electrode, E 1 and down through the drift region of the detector.
At the completion of the drift period, ions are generated in the reaction chamber from the dual opposing corona pins 20 and 22 by the action of a high frequency, high voltage at each of the pins 20 and 22 . The average voltage of the corona pins 20 and 22 is maintained at the level of the reaction chamber 16 surrounding them through the high value resistor R 1 and R 2 . Additionally, high voltage at high frequency (>1 MHz) is fed to the pins 20 and 22 through small value capacitors C 1 and C 2 from the high voltage transformer T 1 which is supplied in turn form the gated oscillator O 1 . Ions of both polarities are formed in the plasma between the pins 20 and 22 and the ionic population builds up without being discharged on the pins 20 and 22 themselves since the relative polarity of the pins 20 and 22 reverses before most of the ions have sufficient time to reach the pins 20 and 22 and discharge. The ionic density increases for a few hundred microseconds after which the gated oscillator O 1 is switched off by the action of the one-shot pulse generator G 1 . At this point the pin voltages return to the same voltage as the walls of the reactor 16 . The positive and negative ion populations are approximately equal and diffuse outwards from the region of the plasma into the rest of the reaction chamber 16 where interaction with molecules of interest occur.
The variable delay circuit 38 times out after a period variable from a few tens of microseconds to a few milliseconds, after which the one-shot pulse generator G 1 again causes the voltage of the reaction chamber 16 and pins 20 and 22 to increase above that of the grid electrode E 1 . This in turn ejects ions from the reaction chamber 16 into the drift region 26 and the process starts over again.
While the invention has been described with respect to a preferred embodiment, it is apparent that various changes can be made without departing from the scope of the invention as defined by the appended claims.
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An ion trap mobility spectrometer is provided with a reaction chamber and a drift chamber. Ions are produced in the reaction chamber by high voltage electronic pulses. More particularly, the ions are formed periodically and are allowed to thermalize in a field-free environment of the reaction chamber. The ions then react with molecular species in the gas phase in the reaction chamber. After a short period, the ions are pulsed into the drift section and are collected on a collector electrode disposed at the end of the drift chamber remote from the reaction chamber. The reaction period may be varied to sample the ion population at different intervals. This enables the ion-molecule reactions to be monitored as the ion population approaches equilibrium. The monitoring results can be used to determine differences between reacting species because the molecular ion population varies at different time points approaching equilibrium. This in turn provides improved identification of target materials.
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FIELD OF THE INVENTION
The present invention relates to an antenna diversity receiver for radio communication systems, and more particularly to a low-complexity antenna diversity receiver having implemented on a single receiver unit a plurality of inter-switchable diversity schemes. Furthermore, this invention relates particularly to an antenna diversity receiver especially suitable for use as a portable handset for Personal Communication Systems (PCS), such as Time Domain Multiple Access (TDMA) Communication Systems.
BACKGROUND OF THE INVENTION
It is well known that antenna diversity can improve the reception quality of communications in a wireless environment and yield increased system capacity. Conventionally, selection diversity is the simplest diversity scheme which operates on the principle of selecting the antenna diversity branch which provides the strongest received signal level or the best eye-opening. However, it is known that selection diversity does not provide any useful gain in a line-of-sight (LOS) environment since the two branches are correlated.
In a recent paper by Cox and Wong, “Low-Complexity Diversity Combining Algorithm and Circuit Architectures for Co-channel Interference Cancellation and Frequency Selective Fading Mitigation”, IEEE Trans. Comm. Vol, 44, no 9, pp. 1107-1116, September 1996, it is shown that two antenna optimum-combining diversity produces a signal-to-interference ratio (SIR) improvement of at least 3-dB over conventional two-antenna selection diversity in Personal Access Communication Systems (PACS). This is attractive since combining diversity can be applied to cancel co-channel interference and boost the desired signal even in an LOS environment.
Qualitatively speaking, in an LOS environment, an optimum-combining receiver adjusts the joint signal of a plurality of antennas, resulting in an adaptive joint antenna pattern or polarization which attenuates co-channel interference while amplifying the desired signal. In a multi-path environment, the antennas may be receiving signals from separate paths and this picture is not entirely applicable, but the concept is the same.
While optimum-combining diversity offers attractive performance improvement over selection diversity, it is noticed that existing antenna diversity researches concentrate on selection diversity. Such a preference is probably due to that fact that many of the so-called adaptive antenna array solutions rely on algorithms which require well characterised antenna patterns. In contrast, most mobile PCS handset antennas possess patterns which are not carefully controlled and are quite dependent on the position of the antenna with respect to the user's hand and head. Thus, if optimum-combining diversity is to be devised and implemented on mobile PCS receiver handsets, the first task would be to seek optimum-combining diversity algorithms which do not require well characterised antennas as a prerequisite.
Hitherto, system complexity together with the associated power consumption, cost and size has been a significant barrier to the wide-spread commercial implementation of diversity schemes in PCS portable handsets since most proposed diversity handset schemes require one receiver chain for each branch of diversity which means that receiver circuitry from RF to baseband has to be duplicated. This dual receiver chain design approach is contradictory to the industrial trend of circuit simplification and consumer appetite of miniaturisation and cost reduction. This limitation, unless circumvented, would continue to hinder implementation and further development of diversity schemes in mobile handsets.
In the Cox & Wong publication above, there is shown a symbolic diagram, i.e. FIG. 1, which discloses the concept of a simplified ideal diversity receiver design in which the RF signal from two antenna branches are combined after level adjustment but before further processing presumably by a single channel device for baseband processing. However, this disclosure merely shows a future receiver topology hopefully to be implemented but the underlying algorithm proposed in that publication does not actually support implementation of a diversity receiver using single channel baseband signal processing.
Furthermore, while selection diversity algorithm does not offer significant signal quality improvement in the circumstances mentioned above, it is nevertheless very fast and energy efficient. In circumstances where the signal quality received by one of the antennas is superbly high, selection diversity would be beneficial and it would be highly desirable that the simpler selection diversity can be chosen and utilised. Thus, it would be highly desirable if a diversity receiver handset can accommodate a number of modes of diversity algorithms which can be chosen according to the reception conditions. This would of course require the presupposition that the prime constraints of low-cost, low-complexity and low-weight are observed.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a low-complexity antenna diversity receiver design consistent with the prime design constraints, i.e. low-cost, low-complexity and low-weight, which is particularly suitable for handset implementation in PCS. To be implemented as a practical and sophisticated mobile PCS handset, it would be appreciated that the design has to meet the following practical design constraints:—
Firstly, the design should utilise only a single receiver chain and baseband combining processor together with standard baseband processing techniques.
Secondly, the only additional RF frontend components required are low-cost passive components for combining RF signals received through a plurality of antenna branches at the RF front-end.
Thirdly, the system is sufficiently robust to handle poorly-defined, user dependent antenna patterns.
Fourthly, the system is capable of providing several modes of diversity algorithm on single receiver without physically changing the hardware or baseband processing, and can choose the most appropriate diversity mode given the mobile usage and signal environment. For convenience, such a receiver would be referred hereinafter to as “multi-diversity receiver”.
Finally, the techniques can be applied to an increased number of antennas, though at the cost of decreased mobility and lower tolerance to fading.
According to the present invention, there is therefore provided A portable receiver for time division multiplexing access (TDMA) personal communication systems in which a wanted signal burst and a plurality of unwanted signal bursts are transmitted in a time-multiplexed manner within the same signal frame comprising first and second antenna diversity branches, signal combining means and signal processing means, wherein each said antenna diversity branch comprises a low-noise amplifier and means for signal amplitude variation and one of said diversity branches comprises phase shifting means; said signal combining means is adapted to combine the signal outputs from said first and second diversity branches before said signal outputs have undergone any frequency conversion, and said signal processing means is adapted to process the signal output from said signal combining means.
Preferably, the receiver further comprises controlling means, wherein said controlling means is adapted to control said means for signal amplitude variation and said means for adjusting phase shift, the amount of amplitude to be varied and the phase to be shifted being dependent on the signal quality (SQ) of unwanted signal bursts which were respectively received by said first and second diversity branches.
Preferably, said signal quality is a factor indicating the eye-opening of the received unwanted signal bursts and is preferably determined by using a square-law symbol timing
Preferably, wherein said receiver comprises means to select a diversity scheme among a plurality of diversity schemes comprising selection diversity (SD), equal-gain combining (EGC) and interference-reduction combining (IRC) algorithms.
According to another aspect of the present invention, there is described a portable receiver for time division multiplexing access (TDMA) personal communication systems in which a wanted signal burst and a plurality of unwanted signal bursts are transmitted in a time-multiplexed manner within the same signal frame comprising first and second antenna diversity branches, signal combining means, signal processing means and controlling means, wherein each said antenna diversity branch comprises a low-noise amplifier and means for signal amplitude variation and one of said diversity branches comprises phase shifting means; said signal combining means is adapted to receive and combine the signal outputs from said first and second diversity branches, said signal processing means is adapted to process the signal output from said signal combining means, and said controlling means is adapted to control said means for signal amplitude variation and said means for adjusting phase shift, the amount of amplitude to be varied and the phase to be shifted being dependent on the signal quality (SQ) of unwanted signal bursts which were respectively received by said first and second diversity branches.
In yet another aspect of the present invention, there is also described an algorithm for operating an antenna diversity receiver comprising i) determining the signal quality of said first and second diversity branches using unwanted signal bursts by firstly enabling said first and substantially disabling said second branch, ii) measuring the first signal quality of the burst received by first branch, secondly by enabling said second branch and substantially disabling said first branch, measuring the second signal quality of the burst received by second branch; iii) comparing the signal qualities thus measured against a pre-determined threshold value, selecting selection diversity if either of said signal qualities exceeds said threshold value and selecting combining diversity if the signal qualities of the signals or their combination are below the threshold value but above a second predefined threshold value which corresponds to signal which are too poor for demodulation, and iv) searching for better signal if the signal qualities of the signals and their combination are below the threshold value which corresponds to signal which are too poor for demodulation.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be explained and illustrated in better detail by way of examples only and with reference to the accompanying figures, in which:—
FIG. 1 is a block diagram showing a two-antenna branch multi-diversity receiver,
FIG. 2 shows a typical TDMA signal frame structure conforming to PACS standard for PCS communication,
FIG. 3 shows a flowchart of a multi-diversity receiver algorithm with two antennas,
FIG. 4 shows the simulation results for link performance under flat fading,
FIG. 5 shows the simulation results for link performance under flat fading with co-channel interference, and
FIG. 6 shows the simulation results for link performance under frequency selective fading.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention is a two-antenna multi-diversity receiver system having implemented a plurality of inter-switchable diversity modes, including selection diversity (“SD”), equal-gain combining (“EGC”) and interference-reduction combining (“IRC”). The expression “multi-diversity” used in the present context is merely intended to indicate a receiver pedigree which is characterised by its ability to select a diversity algorism or scheme among a plurality of pre-installed diversity algorithms or schemes. The hardware of this system is only marginally more complex than existing non-diversity receivers and its complexity is quite comparable to that of a receiver implementing only selection diversity, while achieving performance comparable to that offered by more complex systems under quasi-static multi-path channel and interference conditions.
Hardware
The multi-diversity receiver shown in FIG. 1 comprises two antennas, Ant. 1 & Ant. 2 , each followed by a low-noise RF amplifier (LNA). Conventional antennas meeting the spatial or polarization diversity requirements (un-correlated in a multipath environment) and conventional low-noise RF amplifiers meeting pre-determined performance criteria or technical specifications would be suitable for used. The amplified signals, after appropriate amplitude adjustment and phase shifting, for example by a pair of controllable variable signal attenuators and a phase-shifter, is combined into a single signal stream by an RF-combiner. The signal stream thus combined is then processed by a front-end RF circuit which down-converts the RF-signal so that it can be processed by a demodulator and further operated on by a baseband processor which would in turn control the amplitude attenuators and the phase shifter.
The most noticeable extra hardware components which are to be added to a conventional selection diversity receiver system in order to convert the same into a multi-diversity receiver are two RF attenuators, a RF phase-shifter, and an RF signal combiner. Voltage-controlled variable RF-attenuators having attenuation range between 0-20 dB and a voltage-controlled RF phase-shifter having a shifting range of 0-360 degrees are selected for the present embodiment for illustration purposes and convenience only. Other types of attenuator or shifter with the appropriate ranges can of course be used.
Referring to FIG. 1, a variable RF attenuator is placed after the LNA in each diversity branch for relative amplitude scaling, introducing a maximum possible amplitude variation of 40 dB across the two branches. The phase shifter is only required in one of the two diversity branches to introduce relative phase shifting between the signal streams in the two branches. The resulting signals, after attenuation, phase shift or a combination thereof, are then summed at the signal combiner, fed into the RF front-end circuit for down-conversion and then to be processed by the baseband processor which in turn controls the variable attenuators and the phase shifter via some conventional interfaces.
Fully-Digital TDMA Burst Demodulator
For ease of understanding and because of the importance of TDMA systems in current PCS, the preferred embodiment of multi-diversity receiver architecture is explained with reference to a receiver which is compatible to and designed to operate under TDMA environment for PCS communications, such as PACS, WACS, GSM, PHS, DECT and other like systems. However, it should also be appreciated that the present receiver methodologies, concepts and topologies would equally be applicable for performance improvements of any PCS systems, such as direct-sequence or frequency-hopped systems, as well as TDMA systems.
For sake of completeness and clarity, some basic parameters of the selected TDMA environment together with a preferred demodulation technique are now described. The example transmission environment selected for the present illustrative purposes is the US low-tier PACS standard using π/4 DQPSK modulation, with 384 kbps channel bit rate, 120 bits per time slot, 8 time slots (bursts) per frame, 312.5 μs burst duration and 2.5 ms frame duration, i.e. a frame rate of 400 Hz. The PACS signal downlink frame structure of this system is shown in FIG. 2 . In this example implementation, π/4 DQPSK modulation and square-root raised cosine (α=0.5) pulse shaping is used. The receiver also uses two square root raised cosine (α=0.5) filters for in-phase (I) and quadrature (Q) baseband signal to match the transmitter for optimal performance in additive white Gaussian Noise (AWGN) environments. It also follows that other digital phase modulation systems can be treated similarly.
The preferred signal demodulation technique which is adopted in the instant system for explanation purposes is the fully digital coherent demodulation technique proposed by Chuang and Sollenberger in “Burst Coherent Demodulation with Combined Symbol timing, Frequency Offset Estimation, and Diversity Selection”, IEEE Trans. On Communication, Vol. 39, no. 7 July 1991, and in “Low-overhead Symbol Timing and Carrier Recovery for TDMA portable Radio Systems”, IEEE Trans. On Communication, vol. 38, no. 10, pp. 1886-92, October 1990.
This coherent demodulation technique is unique and preferred because it jointly estimates both symbol timing and carrier frequency offset by operating on an individual TDMA burst without requiring a training sequence. These estimates produce a signal quality factor (SQ) measurement which is a good indicator of the degree of signal impairment caused by noise, delay spread or interference which closes the eye-opening of the detected signals. Unlike using the maximum average eye-opening as symbol timing as suggested in the above Chuang and Sollenberger paper of 1991, square-law symbol timing scheme as proposed by J. G. Proakis in his book “Digital Communications”, 3 rd ed., New York, McGraw-Hill, 1995, is used to estimate timing because of its superior performance. The values of I and Q thus obtained at the sampling output are then used to calculate the SQ and carrier phase (φ). A novel low-complexity diversity combining processor is added into the receiver to control the combining circuits. At the same time, the signal strength is measured through received signal strength indicator (RSSI) circuits.
A low IF bandpass signal at 768 kHz (4 times the symbol rate) is sampled with an A/D converter at 3.072 MHz (4 times the IF), resulting in an oversample of 16 samples per symbol. This is required to achieve symbol timing recovery, signal quality measure, frequency offset estimation and carrier phase recovery without overhead, as suggested in the Chuang and Sollenberger paper above. With the same downconverter architecture, coherent and differential detection can be achieved for π/4 DQPSK.
While frequency offset estimation is not addressed in this implementation, it can for example be removed either through a RF frequency synthesiser or baseband frequency estimation. Since signal bursts for PACS and the like standards are very short relative to channel variation, a quasi static channel approximation can be assumed. Such an assumption means that the channel is static during the burst period is realistically applied to a flat fading study. It should be appreciated that the assumption of a quasi-static channel is used through out this description and in the simulation work that follows.
Antenna Diversity Modes
Most PCS downlinks, including PACS, utilise continuous time division multiplex (TDM) transmission which is particularly known for the increase in transmission rate by time multiplexing data from a number of sources. A characteristic feature of TDM transmission is that, within a time frame, there are a number of extra time-slots in addition to the time-slot allotted to the burst which contains the wanted communication burst.
Referring to FIG. 2, each signal frame duration is 2.5 ms and comprises eight slots each of 312.5 μs duration. Each such 312.5 μs time slot is designated to transmit communication a data burst of 120 bits.
Thus, up to eight communication bursts, usually all originating from different sources, can be transmitted within a single frame. Assuming for convenience that burst B 0 in the third time slot of the instant frame is the desired communication burst which is preceded by a plurality of un-wanted signal bursts, namely for example B 3 & B 4 from the previous frame and B 2 & B 1 from the present frame respectively, which precede the desired burst B 0 . It will become apparent below that these seemingly irrelevant data bursts, i.e. B 1 -B 4 , can be utilised to determine the channel and receiver parameters and set the diversity combining parameters A 1 , A 2 , θ, i.e., the attenuation and the phase shifting factors in FIG. 1 .
Upon determination of the parameters from the seemingly irrelevant bursts, the appropriate diversity modes, i.e. SD, EGC and IRC, which is anticipated to give the best reception according to some pre-determined criteria is to be selected and implemented for instantaneous reception of the desired burst. The manner how this is done is explained below.
In the description to follow, a general description of the various diversity algorithms which are applicable in a diversity receiver are discussed, the symbols P i , SQ i and φ i stand respectively for the received signal power, signal quality and carrier phase of the ith diversity branch.
Diversity Mode I: Selection Diversity (SD mode)
In this diversity mode, the receiver simply selects the diversity branch which has the best signal quality for demodulation. Selection of the diversity branch is usually based on a signal quality factor (SQ) which indicates the quality of the received signal with reference to the signal strength or eye-opening of the received signal. As eye-opening is widely accepted to be the more accurate indication of signal impairment, it will be used in the present embodiment.
In this mode, the SQ of the first and second diversity branches is determined independently and sequentially by any two preceding unwanted bursts, for example B 2 & B 1 above. The branch having the better SQ is selected for demodulating the subsequently arriving desired communication burst B 0 . The following provides an example of steps which could be used for independently obtaining the SQ and selecting the better antenna diversity branch in the SD mode.
Determining the SQ of first branch:
Firstly, the SQ of the first antenna branch, Ant. 1 , is determined by evaluating the preceding burst B 2 which is received through Ant. 1 . This is done by setting A 1 =1 (0 dB attenuation), A 2 =0.1 (20 dB attenuation) and θ=0° (no phase shit). The SQ of the first branch, SQ 1 , as obtained from the received burst B 2 , is then calculated.
Determining the SQ of second branch:
Secondly, the SQ of the second antenna branch, Ant. 2 , is determined by evaluating another preceding burst B 2 which is received through Ant. 2 . This is done by setting A 1 =0.1 (−20 dB), A 2 =1 (0 dB) and θ=0°. The SQ of the second branch, SQ 2 , as obtained from the received burst B 1 , is then calculated.
Communication burst reception:
After SQ 1 and SQ 2 has been determined, the antenna branch having the larger or better SQ is selected to receive and demodulate the desired burst, B 0 .
Diversity Mode 2: Equal-Gain Combining Mode (EGC mode)
Predictions and simulation results show that EGC provides performance advantage in a flat fading environment in which noise is the dominant and at a constant level. In this mode, the signals received by the two antenna are subject to equal amplification and the overall noise figure is reduced by having the phase of the signals from the two branches equalised before summing. EGC is useful for minimising noise figure in the present embodiment since attenuators rather than variable gain amplifiers are used. In this mode, the phase of the signals received via the two branches are first determined by utilising a number of unwanted bursts and their phases are then equalised by relative phase shifting. Since A 1 and A 2 can be set 0 dB, the key remaining process is then to have the signals in the two branches co-phased before combining.
Co-Phasing
Local crystal oscillators are known to have very high short-term stability. It can therefore be safely assumed that its frequency and phase remain constant during several bursts and can be used as a phase reference.
Firstly, Ant. 2 is disconnected and Ant. 1 is selected to receive a preceding unwanted burst B 2 , and the phase Φ 1 is recovered. Secondly, Ant. 1 is disconnected and Ant. 2 is selected to receive another preceding unwanted burst B 2 and phase Φ 2 is recovered. Here, the phases Φ 1 and Φ 2 have an ambiguity equal to an integer multiple of 90 degrees introduced during the phase recovery process. This ambiguity causes no problems in coherent detection since it can be removed by deferential decoding. However, the absolute phase difference between the two branches are required if they are to be properly co-phased.
Now, let Φ=Φ 1 −Φ 2 (phase difference with ambiguity), and θ equals the true phase difference with no ambiguity. In other words, the exact phase difference θ equals to one of the values of Φ−180, Φ−90, Φ or Φ+90. To remove the ambiguity, an additional burst B 1 is employed. This burst B 1 is divided into four equal periods during which the four possible phase values above are tested for combined signal power using RSSI circuit. The phase yielding the smallest power is then phase inverted (+180°) to yield co-phasing, since it is much easier to detect a minimum rather then to compare for a maximum.
Algorithm for Determining Phase Shift for Co-Phasing
The following provides an example of the steps which could be used as a reference to operate on the unwanted bursts B 3 -B 1 for the co-phasing procedure.
B 3 : Firstly, Ant. 1 is selected and Ant. 2 substantially disconnected by setting A 1 =1 (0 dB), A 2 =0.1 (20 dB attenuation) and θ=0°. SQ 1 and Φ 1 are calculated from the unwanted burst B 3 .
B 2 : Secondly, Ant. 2 is selected and Ant. 1 substantially disconnected by setting A 1 =0.1 (−20 dB), A 2 =1 (0 dB) and θ=0°. SQ 2 and Φ 2 are calculated from the unwanted burst B 2 .
B 1 : Thirdly, during the 312.5 μs duration of burst B 1 , the four possible phase difference values, i.e. Φ−180, Φ−90, Φ and Φ+90, are tested and the one which yields the smallest combined power after phase inversion (+180°) is then the exact phase difference which will be used to provide phase shifting in the second branch before the signals are combined.
B 0 : Finally, A 1 and A 2 are both set to 0 dB and the phase shift is set equal to θ, the true phase difference. The desired communication burst B 0 is then received and demodulated.
Diversity Mode 3: Interference-Reduction Combining
In a high capacity PCS, it is known that, for a given bandwidth, co-channel interference (CCI) limits system capacity. Usually, CCI is dominated by one co-channel interferer because of shadowing phenomenon, which is known to have a log-normally distributed local mean of received signal power. In order to cancel the primary source of CCI, it is preferable that the attenuating factors A 1 and A 2 are adjusted so that the interferences I 1 and I 2 from each of the branches are substantially equal in amplitude. The adverse effect of the interference can then be substantially eliminated or cancelled out by out of phase addition.
It is known, for example from the Cox and Wong paper, that Signal-to-Interference Ratio (SIR) and SQ are related. In particular, when SIR is between 7-13 dB, simulation has shown that there exists an approximate linear logarithmic relationship between SIR and SQ which is given by:
SIR ( dB )= S/I ∞ 4+38 SQ ( dB ) EQ. 1
Now, since SIR 1 = S 1 I 1 , P 1 = S 1 + I 1 = I 1 ( 1 + SIR 1 ) EQ .2 SIR 2 = S 2 I 2 , P 2 = S 2 + I 2 = I 1 ( 1 + SIR 2 ) EQ .3
After the received signals have been attenuated, the post attenuation interference then becomes:
I′ 1 =A 1 I 1 ,I′ 2 =A 2 I 2 EQ. 4
In order to cancel the primary source of CCI, the post attenuation interferences I′ 1 and I′ 2 need to be equalised and then added out-of-phase. To make I′ 1 equal to I′ 2 , the ratio, R, between the attenuator factors in the first and second antennas must be equal to the inverse of the ratio between the interfering power received through the first and second antennas. That is: R = A 1 A 2 = I 2 I 1 = P 2 ( 1 + SIR 1 ) P 1 ( 1 + SIR 2 ) EQ .5
The IRC algorithm comprises three major steps:—the initial step, optimising search, and coherent demodulation. The initial step provides a starting step for optimisation by estimating the attenuating factors A 1 and A 2 which will substantially equalise the interfering power by measuring the received power P and determining the signal quality SQ i of preceding bursts according to the above relationships. After the attenuation factors are determined, the necessary phase shifting required to attain optimum interference cancellation is determined according to EQ. 5. In the optimising search algorithm, further refinement of interference cancellation is searched for by varying the phase-shift in pre-defined steps to look for best results. After the optimum phase shift is identified, the desired burst B 0 will then be demodulated.
The optimising search determines parameters for optimal interference reduction and tracks channel variation. Finally, coherent detection then recovers the received data and check the cyclic redundance check (CRC) bits and co-channel interference control (CCIC) bits to determine the next operation. The following provides an example of the steps to be taken to implement the algorithm in the preferred receiver of the present example.
The Initial Step:
B 4 : Firstly, Ant. 1 is selected and Ant. 2 substantially disconnected by setting A 1 =1 (0 dB), A 2 =1 (−20 dB) and θ=0°. P 1 and SQ 1 are then be determined from the received burst, B 4 , and the phase Φ 1 is recovered.
B 3 : Secondly, Ant. 2 is selected and Ant. 1 substantially disconnected by setting A 1 =0.1 (−20 dB), A 2 =1 (0 dB) and θ=0°. P 2 and SQ 2 are likewise determined from the received burst, B 3 , and the phase information, Φ 2 , is recovered. The value of the true phase difference, θ, which would result in co-phasing of the signals, and therefore noise figure reduction, is then obtained by trying the values of Φ=|Φ 1 −Φ 2 | against the four possibilities mentioned in the EGC algorithm above.
B 2 : having determined the ratio, R, from the previous two bursts and using EQ 5, the signal received during this burst will be combined accordingly by setting the larger of A 1 and A 2 equal to 1 (i.e., 0 dB) so that the other attenuating factor will be a fraction of and not exceeding unity, thereby facilitating the use of attenuators only.
The Optimising Step:
B 1 : having combined the signals above with the amplitude ratio, R, the next step is to determine the relative phase-shift between the branches which will give the most favourable interference cancelling performance. In order to ascertain such a phase shift in a non-exhaustive manner to save time and power, the phase shifter is set to step through a combination of pre-defined discrete phase-offsets steps to locate the optimal phase shift. To expedite this search, the phase shift is confined to within 90 degrees of the initial phase shift. θ 0 , obtained above by first adjusting θ 1 =θ 0 +45 and θ 2 =θ 0 −45. This will give a good indication of which incremental phase shift direction would give a better factor, SQ, for the demodulated signal in order to determine the next search.
A Multi-diversity Receiver Algorithm
A preferred multi-diversity receiver algorithm comprising a plurality of diversity modes together with the criteria for selection thereof will now be explained in more detail, and with particular reference to FIG. 3 .
This algorithm comprises three major steps: the characterising step determines the type of diversity to be adopted on the basis of measured SQ, the diversity optimisation step to optimise the receiver parameters and the demodulation step to demodulate the desired burst when certain signal quality indicia is met. The following provides an example of the steps to be taken to implement the algorithm in the preferred receiver of the present example.
The Initial Set-up:
B 3 : Firstly, Ant. 1 is selected and Ant. 2 substantially disconnected by setting A 1 =1 (0 dB), A 2 =0.1 (−20 dB) and θ=0°. P 1 and SQ 1 are then be determined from the received burst, B 3 , and the phase Φ 1 is recovered.
B 2 : Secondly, Ant. 2 is selected and Ant. 1 substantially disconnected by setting A 1 =0.1 (−20 dB), A 2 =1 (0 dB) and θ=0°. P 2 and SQ 2 are likewise determined from the received burst, B 2 , and the phase information, Φ 2 , is recovered. The value of the true phase difference, θ, which would result in co-phasing of the signals, and therefore noise figure reduction, is then obtained by trying the values of Φ=|Φ 1 −Φ 2 | against the four possibilities mentioned in the EGC algorithm above.
B 1 : having determined the ratio, R, from the previous two bursts and using EQ 5, the signal received during this burst will be combined accordingly by setting the larger of A 1 and A 2 equal to 1 (i.e., 0 dB) so that the other attenuating factor will be a fraction of and not exceeding unity, thereby facilitating the use of attenuators only.
The Diversity Optimization:
Having obtained the various channel characteristics from these preceding bursts, the signal quality factors obtained from the above steps are compared against a predefined signal quality threshold level, SQ sd , above which selection diversity is to be used. If either SQ 1 or SQ 2 is above that threshold, reception is good and selection diversity can be adopted subsequently. If none of SQ 1 or SQ 2 is above the selection diversity threshold SQ sd , an optimum combining algorithm will be activated and either an EGC or an IRC algorithm may be used to achieve optimum signal recovery. The demodulated signal thus obtained has to be satisfactorily tested against CRC and CCIC check, only if both tests are passed would the demodulated signal be accepted as a useful burst.
If the demodulated signal fails the CRC check and the SQ is below a minimum threshold level, SQ min , the signal quality is too poor and this may indicate that the search is lost. If the CRC check fails but the SQ is above the minimum threshold level, the search will be continued in order to search for improved signal quality.
Where CRC check is passed but CCIC check fails, this means the receiver is locked to a stronger interferer. If this situation arises under selection diversity mode, the processor could then switch it into an IRC or an EGC mode by first going into the initial setup step to obtain the receiver characterising parameters. If the receiver is not under selection diversity, the phase will be inverted to cancel the stronger interferer, and the next frame is processed using the updated algorithm.
Simulation Results:
Performances of various combining diversity algorithms are simulated and the results are shown in FIGS. 4 to 6 . In the simulations, the following conditions, in addition to those already described in the previous sections, are assumed.
Coherent or differential detection,
Jakes model is used for generating correlated slow Rayleigh fading channel,
A single dominant interferer is assumed in co-channel interference environment,
Delay spread effects are accounted for by using two-ray model.
Quantization is not considered but 40 dB SNR is used as a maximum noise margin.
The system is simulated with uniformly distributed symbol timing and a maximum Doppler shift of 6 Hz which corresponds to a walking speed of 2 mph at 2 GHz. RSSI and SQ provide a useful indicator of the channel conditions, and are used by the multi-diversity receiver to switch between the two combining algorithms automatically. Below a predefined threshold, the environment is noise limited and EGC is used. Otherwise the environment is assumed to be CCI-limited and IRC is employed.
As word error rate (WER), instead of bit error rate (BER), is a better performance indicator in a bursty error environment, all simulation results will therefore be given in WER.
Flat Fading Environment
Referring to FIG. 4 . Coherent detection is used here since it achieves an improvement of about 2.5 dB over differential detection under no diversity. Under flat fading conditions, EGC is used since only programmable attenuators, instead of variable voltage amplifier, are used and noise is dominant and at a constant level. In such a case, A 1 =A 2 =0 dB yields the best noise figure and the two branches are co-phased before combining. The simulation results show that EGC provides a 1 dB improvement over SD at WER=0.01. The SD performance results closely agree with those predicted by other researchers.
Flat Fading with CCI Environment
FIG. 5 shows that in a CCI environment, the performance of SD and EGC are close and a substantial improvement of 4 dB over SD and EGC at a WER of 0.01 can be achieved by IRC at a Doppler frequency of 6 Hz. IRC is sensitive to Doppler shift because of the delay introduced by channel measure. When the Doppler frequency is 1 Hz, the SIR improvement increases to 5.5 dB above EGC performance.
Frequency Selective Fading Environment
Just as co-phasing is ineffective in dealing with CCI and delay spread, IRC is not suitable for dealing with multipath delay spread. The simulated results in FIG. 6 show the IRC's irreducible WER performance in frequency selective fading is better than SD and EGC. Normally, delay spread can be a significant factor even when signal power is high. Under such conditions, IRC is used, treating multipath as a variation of CCI.
While the present embodiment discloses a multi-diversity receiver topology having three inter-switchable diversity algorithms implemented on a single receiver, it should be appreciated that the present design is an extremely flexible design which can easily be converted into a receiver having any optional diversity schemes or a combination of a plurality of diversity schemes simply by necessary programming of the baseband processor shown in FIG. 1 and without appreciable change of the underlying hardware configuration.
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A low-diversity antenna diversity receiver suitable for TDMA PCS handset implementation employing two diversity branches. The receiver is capable of selecting a diversity scheme which is anticipated to give optimum signal reception among a plurality of diversity schemes installed on the receiver. This receiver, more conveniently termed multi-diversity receiver comprises a single conventional wireless digital receiver chain augmented with a few additional low-cost passive RF components and minor control circuits. A plurality of diversity algorithms, for example, selection diversity (SD), equal-gain combining (EGC) or interference-reduction combining (IRC) scheme, which are suitable for implementing on this multi-diversity receiver are also described. Simulation results showing performance of this multi-diversity receiver are also presented.
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FIELD OF THE INVENTION
The present invention generally relates to a pairing method, and more particularly to a method of pairing a computer and at least one wireless electronic device.
BACKGROUND OF THE INVENTION
With the wireless transmission technology, such as Bluetooth, infrared, etc., grows into maturity, various wireless electronic devices are gradually instead of the wired devices to form the common computer peripheral devices, such as a wireless mouse, a wireless keyboard or a wireless communication device.
At the first time for a wireless electronic device communicating with a computer, the wireless electronic device needs to be paired with the computer, so as to successfully transmit the data to the computer. A conventional method of pairing a computer 10 installed a Microsoft® Windows® series operating system (OS) and a wireless mouse 21 is illustrated below.
Referring to FIG. 1 , FIG. 1 illustrates a schematic view of a conventional method of pairing a computer and at least a wireless electronic device. A power source of a wireless mouse 21 is activated first and a pairing button (not shown) is pressed to let the wireless mouse 21 generate and transmit a pairing request message. After that, a wireless transmitting function of the computer 10 is enabled, so as to add a wireless electronic device 20 by a build-in utility of the Microsoft® Windows® OS as described from the step S 10 to the step S 12 .
Referring to FIG. 2 , FIG. 2 illustrates a flow chart of a conventional method of pairing a computer and a wireless electronic device. As illustrated in step S 10 , the computer 10 starts to search at least one wireless electronic device 20 adjacent to the computer 10 . Next, the step S 11 is processed to display a searching list 111 on a monitor 11 of the computer 10 as illustrated in FIG. 3 , FIG. 3 illustrates schematic view of a searching list of a conventional method of pairing a computer and at least a wireless electronic device.
The searching list 111 displays all of the searched wireless electronic devices 20 , and each of the wireless electronic devices 20 has a corresponding icon, for example, the wireless mouse 21 corresponds to a mouse icon 210 , the wireless keyboard corresponds to a keyboard icon 220 , the wireless communication device 23 corresponds to a cell phone icon 230 , etc., and thus it is easy to be recognized for selection. When the icon of the wireless electronic device 20 is selected from the searching list 111 , for example, when the mouse icon 210 representing the wireless mouse 21 is selected, the step S 12 as illustrated in FIG. 2 is processed, and thus starting to pair the computer 10 and the wireless mouse 21 .
However, when there are a plurality of wireless electronic devices adjacent to the computer, the correct wireless electronic device usually needs to be selected from a long searching list. Hence, it may waste a lot of time for selection and come out with several wireless electronic devices belong to the same type, such as a plurality of wireless mice, at the same time as well and thus result in difficult selection therefrom. Therefore, it is quite difficult to use and inconvenient.
SUMMARY OF THE INVENTION
The present invention is directed to a method of pairing a computer and at least a wireless electronic device with advantages of time-saving and convenience operation.
In a preferred embodiment, the present invention provides a method of pairing a computer and a wireless electronic device for establishing a connection therebetween and comprising the following steps:
searching at least one wireless electronic device adjacent to the computer;
recording a media access control (MAC) address of the wireless electronic device;
pairing the computer and the wireless electronic device; and
generating a pairing complete message.
In a preferred embodiment, the step of generating the pairing complete message is displaying the pairing complete message on a monitor of the computer.
In a preferred embodiment, the step of generating the pairing complete message comprises displaying the pairing complete message on a monitor of the computer and transmitting a pairing notice signal to the wireless electronic device.
In a preferred embodiment, the wireless electronic device generates a light signal, a sound signal or a vibration signal after receiving the pairing notice signal.
In a preferred embodiment, the step of searching the wireless electronic device adjacent to the computer comprises:
receiving a pairing request message of the wireless electronic device; and
transmitting a request response message according to the pairing request message.
In a preferred embodiment, the step of pairing the computer and the wireless electronic device comprises:
generating an initialization code; verifying the computer to generate a first pairing data; verifying the wireless electronic device to generate a second pairing data; and transmitting the first pairing data to the wireless electronic device and receiving the second pairing data.
In a preferred embodiment, the wireless electronic device is a wireless input device, a wireless audio output device or a wireless communication device.
In a preferred embodiment, the present invention provides a method of pairing a computer and a plurality of wireless electronic devices for establishing connections therebetween and comprising the following steps:
searching the plurality of wireless electronic devices adjacent to the computer, wherein each of the plurality of wireless electronic devices has a media access control (MAC) address; receiving and recording the MAC addresses of the plurality of wireless electronic devices; pairing the computer and a first wireless electronic device of the plurality of wireless electronic devices; generating a pairing complete message; and determining to pair the computer and the a second wireless electronic device of the plurality of wireless electronic devices if receiving a re-pairing request message.
In a preferred embodiment, the step of generating the pairing complete message is displaying the pairing complete message on a monitor of the computer.
In a preferred embodiment, the step of generating the pairing complete message comprises displaying the pairing complete message on a monitor of the computer and transmitting a pairing notice signal to the first wireless electronic device.
In a preferred embodiment, the first wireless electronic device generates a light signal, a sound signal or a vibration signal after receiving the pairing notice signal.
In a preferred embodiment, the step of searching the plurality of wireless electronic devices adjacent to the computer comprises:
receiving a pairing request message of each of the plurality of wireless electronic devices; and transmitting a request response message according to each of the pairing request messages.
In a preferred embodiment, the step of pairing the computer and the first wireless electronic device comprises:
generating an initialization code; verifying the computer to generate a first pairing data; verifying the first wireless electronic device to generate a second pairing data; and transmitting the first pairing data to the first wireless electronic device and receiving the second pairing data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a schematic view of a conventional method of pairing a computer and at least a wireless electronic device.
FIG. 2 illustrates a flow chart of a conventional method of pairing a computer and a wireless electronic device.
FIG. 3 illustrates schematic view of a searching list of a conventional method of pairing a computer and at least a wireless electronic device.
FIG. 4 illustrates a schematic view of a method of pairing a computer and a wireless electronic device according to a first embodiment of the present invention.
FIG. 5 illustrates a flow chart of a method of pairing a computer and a wireless electronic device according to the first embodiment of the present invention.
FIG. 6 illustrates a flow chart of the step S 20 of a method of pairing a computer and a wireless electronic device according to the first embodiment of the present invention.
FIG. 7 illustrates a flow chart of the step S 22 of a method of pairing a computer and a wireless electronic device according to the first embodiment of the present invention.
FIG. 8 illustrates a schematic view of a method of pairing a computer and wireless electronic devices according to a second embodiment of the present invention.
FIG. 9 illustrates a flow chart of a method of pairing a computer and wireless electronic devices according to the second embodiment of the present invention.
FIG. 10 illustrates a flow chart of the step S 30 of a method of pairing a computer and wireless electronic devices according to the second embodiment of the present invention.
FIG. 11 illustrates a flow chart of the step S 32 of a method of pairing a computer and wireless electronic devices according to the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to specific embodiments of the present invention. Examples of these embodiments are illustrated in the accompanying drawings. While the invention will be described in conjunction with these specific embodiments, it will be understood that it is not intended to limit the invention to these embodiments. In fact, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. In the following description, numerous specific details are set forth in order to provide a through understanding of the present invention. The present invention may be practiced without some or all of these specific details. In other instances, well-known process operations are not described in detail in order not to obscure the present invention.
Referring to FIG. 4 , FIG. 4 illustrates a schematic view of a method of pairing a computer and a wireless electronic device according to a first embodiment of the present invention. A computer 30 , a monitor 31 and a wireless electronic device are presented in FIG. 4 . In the present invention, the wireless electronic device may be a wireless input device (such as a wireless mouse, a wireless keyboard, etc.), a wireless audio output device (such as a wireless earphone, a wireless headset, etc.), or a wireless communication device (such as a cell phone, a personal digital assistant (PDA)), etc. In the present embodiment, the wireless electronic device is illustrated as a wireless mouse 40 .
First, a power source of the wireless mouse 40 is activated and a pairing button (not shown) of the wireless mouse 40 is pressed to let the wireless mouse 40 generate and transmit a pairing request message to computer 30 . The pairing request message contains a media access control (MAC) address of the wireless mouse 40 .
Referring to FIG. 5 , FIG. 5 illustrates a flow chart of a method of pairing a computer and a wireless electronic device according to the first embodiment of the present invention. In the step S 20 , the computer 30 starts to search at least one wireless electronic device adjacent to the computer 30 .
Referring to FIG. 6 for the searching process, FIG. 6 illustrates a flow chart of the step S 20 of a method of pairing a computer and a wireless electronic device according to the first embodiment of the present invention. In the step S 201 , the computer 30 receives the pairing request message transmitted by the wireless mouse 40 , and processes the step S 202 in a predetermined period to determine whether the computer 30 receives at least one pairing request message or not. If yes, then process the step S 203 to transmit a request response message to the wireless mouse 40 according to the pairing request message and go to the step S 21 . If not, then the searching process is failure. The wireless mouse 40 switches into a pairing mode when the wireless mouse 40 receives the request response message.
In the step S 21 , the computer 30 obtains and records the MAC address of the wireless mouse 40 by the pairing request message in the step S 20 . Since each of the wireless electronic devices has a set of unique MAC address, the computer 30 may recognize different wireless electronic devices by the MAC address records when the number of the wireless electronic device is a plural.
In the step S 22 , the computer 30 is pairing with the wireless mouse 40 , and the pairing process is similar to the conventional pairing process and simply described in the following description. Referring to FIG. 7 , FIG. 7 illustrates a flow chart of the step S 22 of a method of pairing a computer and a wireless electronic device according to the first embodiment of the present invention.
In the step S 220 , the wireless mouse 40 is switched into the pairing mode to generate and transmit a set of random number.
In the step S 221 , the wireless mouse 40 generates an initialization code by using the random number generated by itself and the request response message in the step S 20 to provide an encrypted environment for verification.
In the step S 222 , the computer 30 switches into the pairing mode and receives the set of random number.
In the step S 223 , the computer 30 generates an initialization code by using the random number from the wireless mouse 40 and the request response message in the step S 20 to provide an encrypted environment for verification.
In the step S 224 , a verification of the computer 30 is processed. The computer 30 generates a set of verification random number and transmits the verification random number to the wireless mouse 40 . The wireless mouse 40 computes the verification random number by using a verification function to generate a response number, and then compiles the response number to the computer 30 to generate a first pairing data. If the response number and the number computed by the computer 30 are the same, then the first pairing data is success, however, if they are different, then the first pairing data is failure.
In the step S 225 , an inverse verification of the wireless mouse 40 is processed. The wireless mouse 40 generates a set of inverse verification random number and transmits the inverse verification random number to the computer 30 . The computer 30 computes the inverse verification random number by using an inverse verification function to generate another response number, and then compiles the other response number to the wireless mouse 40 to generate a second pairing data. If the other response number and the number computed by the wireless mouse 40 are the same, then the second pairing data is success, however, if they are different, then the second pairing data is failure.
After the first pairing data and the second pairing data are generated, the step S 226 is processed to interchange the first pairing data and the second pairing data. After the computer 30 transmits the first pairing data to the wireless mouse 40 and receives the second pairing data from the wireless mouse 40 , the step S 227 is processed to determine whether the first pairing data and the second pairing date are both success or not. If yes, then the computer 30 and the wireless mouse 40 are success in pairing and then the step S 23 is processed. If not, then they are failure to be paired.
Referring to FIG. 5 again, in the step S 23 , the computer 30 generates a pairing complete message 32 , which is displayed on the monitor 31 of the computer 30 for notifying users that the computer 30 and the wireless mouse 40 are success in pairing. Moreover, the computer 30 may further transmits a pairing notice signal to the wireless mouse 40 to let the wireless mouse 40 generate a light signal, a sound signal or a vibration signal, so as to notify users where is the paired wireless electronic device 40 .
Referring to FIG. 8 , FIG. 8 illustrates a schematic view of a method of pairing a computer and wireless electronic devices according to a second embodiment of the present invention. A computer 50 , a monitor 51 and two wireless mice 61 , 62 are presented in FIG. 8 . First, a power source of the wireless mouse 61 is activated and a pairing button (not shown) of the wireless mouse 61 is pressed to let the wireless mouse 61 generate and transmit a pairing request message, wherein the pairing request message contains a media access control (MAC) address of the wireless mouse 61 .
Referring to FIG. 9 , FIG. 9 illustrates a flow chart of a method of pairing a computer and wireless electronic devices according to the second embodiment of the present invention. In the step S 30 , the computer 50 starts to search wireless electronic devices adjacent to the computer 50 , wherein the wireless electronic devices in the present embodiment comprise the wireless mouse 61 and the wireless mouse 62 . The wireless mouse 61 and the wireless mouse 62 have different MAC addresses.
Referring to FIG. 10 for the searching process, FIG. 10 illustrates a flow chart of the step S 30 of a method of pairing a computer and wireless electronic devices according to the second embodiment of the present invention. In the step S 301 , the computer 50 with wireless transmission function receives the pairing request messages transmitted by the wireless mouse 61 and the wireless mouse 62 , and processes the step S 302 in a predetermined period to determine whether the computer 50 receives at least one pairing request message or not. If yes, then process the step S 303 to transmit request response messages to the wireless mouse 61 and the wireless mouse 62 according to the pairing request messages and go to the step S 31 . If not, then the searching process is failure. The wireless mouse 61 and the wireless mouse 62 switch into a pairing mode when the wireless mouse 61 and the wireless mouse 62 receive the request response messages.
In the step S 31 , the computer 50 obtains and records the MAC addresses of the wireless mouse 61 and the wireless mouse 62 by the pairing request messages in the step S 30 . Since the wireless mouse 61 and the wireless mouse 62 have different MAC addresses, the computer 50 may recognize the wireless mouse 61 and the wireless mouse 62 by the MAC address records.
In the step S 32 , the computer 50 is pairing with one of the wireless mouse 61 and the wireless mouse 62 . For example, the computer 50 is pairing with the wireless mouse 61 , wherein the pairing process is similar to the conventional pairing process and simply described in the following description. Referring to FIG. 11 , FIG. 11 illustrates a flow chart of the step S 32 of a method of pairing a computer and wireless electronic devices according to the second embodiment of the present invention.
In the step S 320 , the wireless mouse 61 is switched into the pairing mode to generate and transmit a set of random number.
In the step S 321 , the wireless mouse 61 generates an initialization code by using the random number generated by itself and the request response message in the step S 30 to provide an encrypted environment for verification.
In the step S 322 , the computer 50 switches into the pairing mode and receives the set of random number generated by the wireless mouse 61 .
In the step S 323 , the computer 50 generates an initialization code by using the random number from the wireless mouse 61 and the request response message in the step S 30 to provide an encrypted environment for verification.
In the step S 324 , a verification of the computer 50 is processed. The computer 50 generates a set of verification random number and transmits the verification random number to the wireless mouse 61 . The wireless mouse 61 computes the verification random number by using a verification function to generate a response number, and then compiles the response number to the computer 50 to generate a first pairing data. If the response number and the number computed by the computer 50 are the same, then the first pairing data is success, however, if they are different, then the first pairing data is failure.
In the step S 325 , an inverse verification of the wireless mouse 61 is processed. The wireless mouse 61 generates a set of inverse verification random number and transmits the inverse verification random number to the computer 50 . The computer 50 computes the inverse verification random number by using an inverse verification function to generate another response number, and then compiles the other response number to the wireless mouse 61 to generate a second pairing data. If the other response number and the number computed by the wireless mouse 61 are the same, then the second pairing data is success, however, if they are different, then the second pairing data is failure.
After the first pairing data and the second pairing data are generated, the step S 326 is processed to interchange the first pairing data and the second pairing data. After the computer 50 transmits the first pairing data to the wireless mouse 61 and receives the second pairing data from the wireless mouse 61 , the step S 327 is processed to determine whether the first pairing data and the second pairing date are both success or not. If yes, then the computer 50 and the wireless mouse 61 are success in pairing and then the step S 33 is processed. If not, then they are failure to pair.
In the step S 33 , the computer 50 generates a pairing complete message 52 , which is displayed on the monitor 51 of the computer 50 for notifying users that the computer 50 and the wireless mouse 61 are success in pairing. Moreover, the computer 50 may further transmits a pairing notice signal to the wireless mouse 61 to let the wireless mouse 61 generate a light signal, a sound signal or a vibration signal, so as to notify users where is the paired wireless mouse 61 .
Further, the pairing complete message 52 further comprises a pairing confirming message, which is displayed as “Is the paired wireless electronic device is correct?”, and thus users may confirm whether the wireless mouse 61 is the correct pairing subject or not; if yes, then a re-pairing request message will not be generated; however, if not, then a re-pairing request message is generated.
In the step S 34 , the computer 50 determines whether a re-pairing request message is received or not. If the wireless mouse 61 is the wireless electronic device desired to be paired, then users may click a button 53 marked as “Yes and complete.” to complete the pairing process, and then the wireless mouse 61 may be normally operated on the computer 50 . If the wireless mouse 61 is not the wireless electronic device desired to be paired, then users may click a button 54 marked as “No and re-pairing.” to transmit a re-pairing request message to the computer 50 and go to the step S 35 . In the step S 35 , the computer 50 confirms the MAC address records, excludes the MAC address record of the wireless mouse 61 , and then reads the MAC address record of the wireless mouse 62 . Thereafter, the step S 32 is processed to pair the computer 50 and the second wireless electronic device 62 .
According to the description of the above-mentioned preferred embodiments, it is obvious that the method of pairing a computer and at least one wireless electronic device of the present invention uses the step of recording the MAC address(s) of the wireless electronic device(s) to replace the step of selecting a correct wireless electronic device from a searching list in the conventional method. Therefore, the present invention may not only save lots of time for selection, but also provide a simple pairing method to avoid difficult selection from several wireless electronic devices belong to the same type that comes out at the same time that result in quite difficult to use and inconvenient.
Although specific embodiments of the present invention have been described, it will be understood by those of skill in the art that there are other embodiments that are equivalent to the described embodiments. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims.
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The present invention discloses a method for pairing a computer and wireless electronic devices including searching at least one wireless electronic device adjacent to a computer; recording a media access control (MAC) address of the wireless electronic device; pairing the computer and the wireless electronic device; and generating a pairing complete message. The present invention saves time of selecting the wireless electronic device from a candidate list and also provides a convenient and easy pairing method.
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[0001] This application claims priority from U.S. Provisional Application Serial No. 60/304,750, filed Jul. 13, 2001. The entirety of that provisional application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention generally relates to providing business consulting services, and more specifically, to a system and method for providing business solutions to clients via the Internet.
[0004] 2. Related Art
[0005] Investing in the right e-commerce solution is often bewildering for businesses and individuals. The right solution could transform a company into an industry leader. The wrong solution, however, wastes time, money, and market share. A poorly conceived website attracts little attention and no new business. While the website languishes in the uncharted depths of the Internet, there's also a very real chance that competitors with better websites will lure customers away. There is thus a need for an effective website strategy.
[0006] In addition, in a world where rapid technological development is the norm, many websites fail to keep pace with the changing expectations of online customers. The inability to come to terms with new technological developments condemns many websites to failure. Companies must embrace new technologies on their websites and use a dynamic presentation to engage the user. Thus, there is a need for a technologically advanced website strategy.
[0007] Entities also need a dynamic and comprehensive e-commerce solution, and at a price well within reach. A website should remember users when they return, and, with an interactive shopping cart system, keep track of the items users want to buy. This familiarity fosters ease-of-use and improves customer loyalty, creating an atmosphere likely to boost sales. What is needed is an opportunity to expand sales through traditional e-commerce, and reduce expense by analyzing the tasks carried out within an organization and applying principles to enhance them. This allows these tasks to be carried out more efficiently and less expensively thanks to the Internet, ensuring major reductions in costs.
[0008] In addition, entities need an effective, comprehensive system and method for accessing remote and off-shore products and services. This system and method should ensure that required standards, quality, and processes are met. For example, it is extremely useful for entities that need websites to access website development services in less expensive areas of the world (e.g., India, China). As another example, it is also useful for entities that need to buy a product (e.g., food) or service (e.g., financial services) to access less expensive sellers or sellers in multiple jurisdictions. Currently, it is very difficult to connect a buyer with a seller in other countries, particularly if the country is a third world country. It is also challenging to deliver a quality product complying with the buyer's expectations.
[0009] Furthermore, high levels of security are required, ensuring that customers' online shopping experience are simple and safe. Thus, there is a need for a website strategy that incorporates security solutions.
[0010] In addition, a website should provide a fully featured administration system that easily allows updating of the range of products offered from the Internet browser, with the ability to add or remove products, change prices or launch special offers at any time of the night or day. Thus, a need exists for a website strategy that incorporates a-simple administrative system.
[0011] The marketing of a website is also important. Money spent developing an online presence is money wasted if the website existence is generally unknown. An important test of success or failure is the number of users a website attracts. Using this benchmark, the overwhelming majority of websites are failures. The chances of a user finding a website without knowing the uniform resource locator (URL) or being directed there by an external agency are low. Many strategies that work well in the physical world are doomed to fail in the electronic marketplace. Conversely, many techniques that would be far too expensive to contemplate in the “real” world are viable propositions on the net, where a potentially massive global audience is within easy reach. There is thus a need for a website strategy that includes advanced traffic-driving services (e.g., database marketing and search engine registration and optimization) and Internet marketing strategies.
SUMMARY OF THE INVENTION
[0012] The present invention meets the above needs in the prior art by providing business solutions that are effective, include technological advances, utilize e-commerce, commerce, offer secure solutions, are simple to administer, incorporate Internet marketing strategies, and provide means for effectively accessing remote (e.g., offshore) products and services. In an embodiment of the present invention, a host helps connect a client (e.g., Canada, the United States) with a developer in a less expensive area (e.g., India, China) with a high profile, state-of-the-art, customized, online website. In other embodiments of the present invention, a host helps connect a client with a product or service (e.g., food, computer hardware, toys) offered in a less expensive area.
[0013] The present invention incorporates a high-efficiency development model. This model has been developed through identifying common components that comprise different client solutions. By breaking out these components and refining them into functional modules that can deliver high functionality, developers around the world can rapidly develop Internet solutions without writing programming code from scratch for each solution. Since each module is developed with great planning and attention to detail, the functionality of these modules meets and exceeds most client requirements. In addition, the model demonstrates great efficiency by using a standardized format for submitting site requirements and content (e.g., a functional design).
[0014] For example, in one embodiment an Internet Consultant (IC) (e.g., independent contractor or employee of a host company) contacts a potential client, completes a business analysis by obtaining information about the client's company and desired website components, and creates a proposal. The client accepts the proposal and the IC and the client define functional modules (e.g., a functional design) tailored to the client so that the host can connect the IC and the client with a programmer (e.g., in a less expensive area) that can create the customized website. Those experienced in the art will realize that the programmer can be a host employee, an independent contractor, or another entity. The business analysis, proposal, and defined functional modules are based upon defined common components that the host has compiled. This is important because when a website is developed off-shore, a major challenge is ensuring that client requirements have been adequately documented, thereby dramatically reduces errors and downtime. The IC and host are versed in a blueprint language so that each party can quickly communicate and assess the components, features, and content of the website. As the architect and the construction worker communicate through shared drafting standards and norms, the functional design accomplishes the same task between the client and the developer of Internet solutions.
[0015] Internet solutions are developed and delivered with building blocks that can be rapidly assembled by developers, ensuring that development times are minimized and the solution is highly cost efficient for the client. This allows the present invention to offer levels of quality, functionality, and cost effectiveness to clients that is unmatched globally.
[0016] The present invention gauges the needs and provides solutions to help a client better do business on the Internet. The present invention works with the client to use practical tools and marketing solutions on the Internet to grow the client's business.
[0017] The system and method of the invention provide ICs with an effective and efficient way of delivering specialized business solutions to their clients via the Internet. The system includes a terminal and a server that are operationally connected to each other through couplings and a network (e.g., the Internet).
[0018] In an embodiment of the invention, a method for delivering specialized business solutions is provided that includes six phases, each of which is completed before moving on to the next phase.
[0019] The first phase is the business analysis phase, during which an IC and/or host establishes rapport with a prospective client and creates a business strategy for a network, such as the Internet, for the client by researching the client business and market.
[0020] The second phase is the functional design phase, during which the IC gathers the client's information to create a network website, including all of the client's functional requirements.
[0021] The third phase is the building phase of the website, during which coding and database integration for the website are produced in accordance with the functional design phase.
[0022] The fourth phase is the testing phase of all the functional requirements of the website to ensure that they meet the client's requirements.
[0023] The fifth phase is the launching phase, which places the website live on a server and registers the website with all appropriate search engines to optimize traffic levels. All client internal and operations processes associated with the website are also implemented and validated during the launching phase.
[0024] The sixth phase is the managing results phase, during which the IC and client meet at regular intervals to review website traffic, to understand which components of the website are successful and which areas may need further review, and to implement marketing and promotional activities. The IC and client can also identify potential subsequent enhancements to the website during the managing phase.
[0025] The features and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference numbers indicate identical or functionally similar elements.
BRIEF DESCRIPTION OF THE FIGURES
[0026] [0026]FIG. 1 illustrates an overview pictogram of system elements in accordance with an embodiment of the present invention.
[0027] [0027]FIG. 2 illustrates an overview of the method for delivering a specialized Internet business solution website to a prospective client, in accordance with an embodiment of the invention.
[0028] [0028]FIG. 3 is a flowchart illustrating business analysis phase 205 , according to an embodiment of the present invention.
[0029] [0029]FIG. 4 is a flowchart illustrating functional design phase 210 , according to an embodiment of the present invention.
[0030] [0030]FIG. 5 is a flowchart illustrating creative concept guideline process 410 , according to an embodiment of the present invention.
[0031] [0031]FIG. 6 is a flowchart illustrating functional requirement process 415 , according to an embodiment of the present invention.
[0032] [0032]FIG. 7 is a flowchart illustrating website plan process 420 , according to an embodiment of the present invention.
[0033] [0033]FIG. 8 is a flowchart illustrating page information sheet process 425 , according to an embodiment of the present invention.
[0034] [0034]FIG. 9 is a flowchart illustrating database guideline 430 , according to an embodiment of the present invention.
[0035] [0035]FIG. 10 is a flowchart illustrating building phase 215 , according to an embodiment of the present invention.
[0036] [0036]FIG. 11 is a flowchart illustrating testing phase 220 , according to an embodiment of the present invention.
[0037] [0037]FIG. 12 is a flowchart illustrating launch phase 225 , according to an embodiment of the present invention.
[0038] [0038]FIG. 13 is a flowchart illustrating managing results phase 230 , according to an embodiment of the present invention.
[0039] FIGS. 14 - 43 are screen shots illustrating use of the system 100 and method 200 , according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The present invention relates to a system, apparatus, method and computer program product for providing website business solutions to clients via the Internet.
[0041] In an embodiment of the present invention, a host organization provides and allows access to a tool that enables clients to order and receive website business solutions via the global Internet. That is, the service provider would provide the hardware (e.g., servers) and software (e.g., database) infrastructure, application software, customer support, and billing mechanism to allow its ICs (e.g., independent contractors, host organization employees) to create guidelines for effective and efficient Websites for clients. The tool is used by the host to create websites based on the guidelines.
[0042] The level of detail collected by the present invention, which has not been seen in any conventional systems, allows ICs the ability to effectively and efficiently provide customized website solutions to clients.
[0043] In an embodiment of the present invention, the host provides a World Wide Web site where an IC, using a computer and Web browser software, can remotely view and receive host information, in addition to submitting information to the host.
[0044] In an alternate embodiment, the tool that provides website business solutions resides, instead of on the global Internet, locally on proprietary equipment owned by a host as a stand alone system software application.
[0045] The present invention is described in terms of the above examples. This is for convenience only and is not intended to limit the application of the present invention. In fact, after reading the following description, it will be apparent to one skilled in the relevant art(s) how to implement the following invention in alternative embodiments.
[0046] The terms “user,” “subscriber,” “customer,” “company,” “business concern,” “broadcaster,” “corporate advertiser,” “advertising agency,” and the plural form of these terms are used interchangeably throughout herein to refer to those who would access, use, and/or benefit from the tool that the present invention provides.
[0047] System Overview
[0048] [0048]FIG. 1 illustrates an overview pictogram of system 100 elements in accordance with an embodiment of the present invention. The system of the invention provides one or more ICs 101 with an effective and efficient way of delivering specialized business solutions to their clients via the Internet. The system includes a terminal 102 and a server 103 that are operationally connected to each other through couplings 105 , 106 , and a network 104 (e.g., the Internet). Terminal 102 includes a user interface to capture information on the client, client business, client market, and client's functional requirements; a memory, operationally coupled to the user interface, to store the captured client's information and functional requirements; and a processor, operationally coupled to a user interface and memory, to create a business strategy and specialized business solutions for the client based on the client's information and functional requirements. The server 103 delivers the business strategy and specialized business solutions to the client via network 104 .
[0049] In this embodiment, the website developer is an employee of the host, and is thus described as the host. In alternative embodiments, the website developer could be an independent contractor, a company different from the host, or another entity.
[0050] Method Overview
[0051] [0051]FIG. 2 illustrates an overview of the method for providing website business solutions to clients, in accordance with an embodiment of the invention. In step 205 , a business analysis is completed by questioning the client, analyzing the client's responses, and preparing a client proposal during the business analysis phase. In step 210 , the business analysis is incorporated into a functional design during the functional design phase. In step 215 , a website is built using the functional design specifications and solutions/code during the building phase. In step 220 , the website is tested by the IC and the client during the testing phase. In step 225 , the website is launched during the launching phase. In step 230 , the website is managed during the managing results phase.
[0052] Business Analysis Phase
[0053] [0053]FIG. 3 is a flowchart illustrating business analysis phase 205 , according to an embodiment of the present invention. The present invention, in order to optimize a client's Internet marketing strategy, employs an Internet business analysis. The business analysis offers a comprehensive overview of an entity's current status. As part of the business analysis, a company's internal workings are thoroughly examined with a view to improving internal efficiencies and streamlining business systems. The business analysis, however, also looks at the company in a broader market context, clearly identifying competitive advantages and target markets, and suggesting ways to increase customer loyalty and retention. By providing the benchmarks by which a website's success can be measured, the business analysis allows the tailoring of an Internet business strategy designed to produce significant return on investment.
[0054] In step 305 , the host or IC makes an initial client contact. This can be through a host website or some other contact (e.g., a telephone call or letter from the IC). For example, the host can post information on the website explaining the method 200 , and asking for client information. The client information can include, for example, contact information, goals and objectives for the client's website (e.g., lead generation, sell products/services to defined market, automate current business practices), websites that have appealed to the client, current client website information (if any), and aspects of a business analysis that interest the client (e.g., how the Internet can increase company revenue, how a client can realize a return on an Internet investment, how to sell products/services to a predefined market, how to decrease company costs by streamlining business functions; how improved business efficiencies will add to business time management).
[0055] In step 310 , the IC completes initial research and analysis. The research and analysis can include client research (e.g., key decision makers, company size, news events affecting the company, key clients), market research (e.g., target market, key industry terminology and trends, key competitors, industry challenges), Internet research (e.g., host-developed websites in the same industry, current client website and its effectiveness, news events regarding how the Internet is affecting the client's industry), and documentation of the research.
[0056] In step 315 , the IC makes a presentation to the client, explaining the host's service and the business analysis. In step 320 , the IC initiates an Internet business analysis by securing client responses to questions related to a desired client website (e.g, Internet familiarity, business practices, and desired Internet features). The business analysis can include, but is not limited to, the following: the company's selling points, sources of growth, competitor information, customer business cycles, business challenges, business accomplishments, network organizations, company publications, mailing list information, marketing information, products or services for sale, promotional information, company branded positioning, customer service information, and customer relationship cultivation information.
[0057] In step 325 , the IC completes the business analysis by interpreting the responses to the business analysis questions using an IC guide. The IC guide provides explanations for the answers desired and received from the business analysis questions.
[0058] In optional step 326 , an estimate verification is completed. The estimate verification is accessed online, and enables the IC to communicate questions regarding functionality, unique customizations, or feasibility requests to the host before obtaining a signed contract with the client. This enables the IC to obtain accurate information (e.g., pricing, delivery time) for the proposal.
[0059] In step 330 , the host incorporates the business analysis into an Internet business solution proposal. The Internet business solution proposal outlines the general and specific possibilities and opportunities the host can offer to the client. The Internet business solution proposal also includes a detailed pricing breakdown and a proposed timeline. The Internet business solution proposal can include, but is not limited to: Internet benefits, consultant services, Internet solutions overview, corporate information and identity, e-commerce solutions (e.g, personal shopping cart technology, sales management tools), product or service presentation, customer communication information, business-to-business commerce, internal communications, customer service, marketing, multimedia website/Internet infrastructure maintenance, training, and pricing.
[0060] In step 335 , the IC presents the Internet business solution proposal to the client and obtains client approval to proceed with the proposal.
[0061] Functional Design Phase
[0062] [0062]FIG. 4 is a flowchart illustrating functional design process 210 , according to an embodiment of the present invention. In step 405 , the IC secures client approval to register or transfer the client's domain name. In step 410 , the IC secures client approval for creative concept guidelines, which controls how the website will look. In step 415 , the IC secures client approval for functional requirement guidelines, which are the specific activities and experiences available to the client or a surfer when using the website. In step 420 , the IC secures client approval for a website plan, which is partially based on the functional requirement guidelines. In step 425 , the IC creates page information sheets identified in the website plan. The specific details of each page are documented to communicate required information to the host. The IC may draw from a storehouse of established page information sheets to streamline IC and host activities. In step 430 , the IC defines database guidelines, which enable communication of known, specific data fields and their logistical groupings that are required for display and functionality within the website. In step 435 , the IC reviews a functional design report, which can also be used throughout the functional design process to gather and document which parts of the functional design process have been completed. The functional design report is a summary or checklist that ensures a complete submission of data and thus helps avoid project delays. In step 440 , the IC submits the functional design package to the host. In an alternative embodiment, the host and IC can access a mail feature that enables communication throughout the functional design process.
[0063] The functional design can be completed online or offline. When online, in an alternative embodiment, the IC has the option to access other features. The IC may save documentation and archive this documentation for future access, in case similar jobs are completed in the future. In addition, the IC has an online ability to access a knowledge base of previously submitted functional designs, in case similar jobs have already been completed. Furthermore, when online, the IC draws from a storehouse of standard website plans, providing greater efficiency to the process. The IC then has the option to modify and re-upload, if needed.
[0064] Creative Concept Guidelines. FIG. 5 is a flowchart illustrating creative concept guideline process 410 , according to an embodiment of the present invention. The creative concept guidelines are defined to help the host and client communicate the look, feel, and style concepts of the website. In step 505 , the client completes website research utilizing IC guidelines, identifying, for example, existing preferred websites and styles.
[0065] In step 510 , the client selects a custom design or fastrack style project path. The custom design allows the client to provide guidelines for a custom website. These guidelines are based on defining a client's approach to the market and reviewing a variety of website styles. The fastrack style allows the client to select among different predesigned styles, colors and layouts created by the host. The fastrack style often results in faster production of the website because custom work is not done and client approvals for the custom design are eliminated.
[0066] If the custom design path is selected, a custom design is completed in step 515 . If the fast-track style path is selected, at least one fast-track style is chosen in step 520 . In step 525 , the custom design or at least one fast-track style is incorporated into the functional design report.
[0067] Functional Requirement Guidelines. FIG. 6 is a flowchart illustrating functional requirement process 415 , according to an embodiment of the present invention. The functional requirements include the specific activities and experiences available to the client or the surfer when using the website. Functional requirements include, but are not limited to: specific Internet applications (SIAs) (e.g., customized and fastrack virtual agency, virtual restaurant, digital dealership, world merchant system); Internet marketing tools (dynamic information system, login system multiple users, file download link, standard form, web board/chat, guest book, online employment system, form based auto responder, text editor, intuitive marketing technology—cookies, dynamic survey system, scrolling marquee, image managers, document management system); creative services (e.g., concept draft, single pages, 360 degree panoramic imaging and hot spot; popups/thumbnail imaging, mouse over, animated text, animated GIF, logo design, individual banner design, corporate identity); database table integration (e.g., database table, database content editors, database search, file upload); production center specific products (e.g., dynamic concept draft, categories, banner system, under construction page, email stationary, 360 imaging, concept draft; corporate bid consulting; multiple fastrack styles, fastrack flash banners, fastrack static banners, educational information system, web board, vertical scrolling marquee, HTML editor, horizontal image scroller, vertical image scroller, event scheduling system, flash options, job information, guest book, forum, e-marketer, virtual travel agency, floating banner, shopping cart, info-links, concept drafts); multi-media and special services (e.g., shockwave/flash); and e-commerce products (e.g., world merchant system, credit card processing system). In another embodiment, package specials, which combine multiple functions into pre-set packages with reduced price, are also offered. In a further embodiment, miscellaneous services (e.g., project management services, design or development services, database analysis, technical management services) are also offered.
[0068] In step 605 , the IC reviews the client Internet business solution proposal to determine which functional requirements the client desires. In step 610 , which is optional, the IC can again review with the client each functional component of the website. For example, one function is to provide sensitive product data access to customers.
[0069] In step 615 , functional data is entered into the functional design report. For each functional requirement or business event, the function or event is broken down into the specific steps required to achieve the function. For example, if the function is to provide sensitive product data access to customers, the specific steps are: selecting product information retrieval function; entering user name and password to access information; accepting/rejecting user name and password; submitting search or product documentation on a specific subject; presenting product list to select from; and selecting an appropriate listed item for viewing.
[0070] Website Plan. FIG. 7 is a flowchart illustrating website plan process 420 , according to an embodiment of the present invention. The website plan communicates the page structure of the website to the host, organizing information into logical groups and functions. In step 705 , the key functions of the website are identified and grouped. In step 710 , each major function is divided into logical steps, and the priority of each function is determined. For example, information on products is presented through categorization, where the IC indicates that categories should be displayed first, then products, then product details.
[0071] In step 715 , footnotes are added to explain functions or conditions for navigation from one page to the next. In step 720 , the function information is incorporated into website plan. In an embodiment of the present invention, the website plan is adjusted to comply with host standards. For example, the website plan could be adjusted to meet certain margin, typeface, and organizational chart requirements. In step 730 , the website plan is sent to the host to help confirm IC and client expectations regarding how the website is to be administered.
[0072] Page Information Sheets. FIG. 8 is a flowchart illustrating page information sheet process 425 , according to an embodiment of the present invention. Creation of the page information sheets can occur in tandem with the website plan creation. The page information sheets document the specific details of each page for the host, and include all the media to appear on a specific page, including direct documentation of text, cross reference of graphics files, and descriptions of all page functions.
[0073] In step 805 , the page title information is completed. The title of the page, which includes keywords, should be as descriptive as possible. In step 810 , the page description is completed. The page description accompanies the page title on results listings from search engines and may influence a surfer to enter the page when reviewing search engine output listings. In step 815 , keywords or keyphrases are identified. In step 820 , the functionality of each page is detailed. These requirements help the host make the page, and are a key component of documentation in the testing process. In step 825 , the text that will appear on the page is included. In step 830 , all image files that will be displayed on the page are cross-referenced. In step 835 , example websites are included to help the host understand the client's desired page design, layout or functionality are documented.
[0074] Database Guidelines. FIG. 9 is a flowchart illustrating database guideline process 430 , according to an embodiment of the present invention. The database element guidelines enable the IC to communicate specific database requirements for display and to drive functions within the website.
[0075] In step 905 , the key functions defined within the functional design guidelines and the website plan are used to identify the key data fields. In step 910 , the data fields are logically grouped to help communicate the data structure to the host. In step 915 , examples of each data field are provided so that the host can better understand the desired data structure.
[0076] In step 920 , the specific functionality of each data field is explained to communicate how the data should be structured and how the data should be presented. In step 925 , the data field information is grouped in a database definition document. In optional step 930 , live data is added. If there are large quantities of data that require uploading to the database prior to a website going live, the IC can attach all client data in a separate spreadsheet. This data can be used in testing and can be available immediately when the website goes live.
[0077] Functional Design Summary Report. The functional design summary report is reviewed to make sure the core pieces of the functional design (e.g., creative concept guidelines, functional requirement guidelines) are completed.
[0078] Screen Shots. FIGS. 14 - 26 are screen shots illustrating the functional design phase, in an embodiment of the present invention. FIGS. 14 - 15 are screen shots illustrating the creative concept guidelines. FIGS. 16 - 17 are screen shots illustrating the functional requirement guidelines. FIG. 18 is an screen shot illustrating the website plan feature. FIGS. 19 - 20 are screen shots illustrating the page information feature. FIG. 21 is an screen shot illustrating the database feature. FIG. 22 is a screen shot illustrating the summary report feature. This screen shot can be accessed at any time to view the status of the creative concept, functional requirements, website plan, page information, and database features. FIGS. 23 - 26 are additional screen shots illustrating the functional design phase.
[0079] Building Phase
[0080] [0080]FIG. 10 is a flowchart illustrating building phase 215 , according to an embodiment of the present invention. The building phase assists the IC and the host in managing the production of the website to ensure effective solution delivery and client satisfaction. The building process emphasizes quality control project management and client involvement, and allows for ensuring acceptance of the functional design, tracking production issues for resolution, reviewing creative concept, layout and development drafts of the website, and managing changes to the scope of the website.
[0081] In step 1010 , the IC submits a new project request to the host. In step 1015 , the host reviews and either rejects or accepts the new project request. If the submission is rejected, in step 1020 , the host notifies the IC as to why the project was rejected (e.g., the submission requires changes, the host cannot support the product request due to resource constraints).
[0082] If the submission is accepted, in optional step 1025 , the IC secures client approval for the logo guidelines. The logo design is a flat (no animation) graphic design prototype of the client's new logo. The IC reviews the logo guidelines, documents any issues using an issue tracking tool (e.g., an online tool), presents the logo to the client, enters required changes in the issue resolution tracking section, and has the client sign the logo approval form once identified changes in the issue tracking tool have been made.
[0083] In step 1030 , the IC secures client approval for the creative concept guidelines. The creative concept is the graphic design prototype, look and feel of the website. The IC compares the creative concept draft to the functional design requirements, documents any issues, presents the draft to the client, enters required changes in the issue resolution tracking section, and has the client sign the approval form once identified changes in the issue tracking tool have been made.
[0084] In optional step 1035 , the IC secures client approval for flash design guidelines. The flash design is an animated sequence that may vary in complexity based on the number of animated actions in the sequence. The flash design may also consist of multiple, distinct sequences that are to appear in different sections of the website. The IC reviews the flash draft, documents any issues, presents the flash to the client, enters required changes in the issue resolution section, and has the client sign the flash approval form.
[0085] In step 1040 , the IC secures client approval for the layout guidelines. The layout is the graphic design of an entire custom website. It is composed of all the pages of the website, unless certain pages are repetitive. The layout displays the color, layout, and navigation of the website. The layout is an opportunity to review all the visual elements of the website before coding. The layout guidelines do not apply to fastrack projects, but only custom projects. The IC reviews the layout draft, presents the layout draft to the client, enters required changes in the issue resolution section, and has the client sign the layout approval form.
[0086] In step 1045 , the IC secures client approval for the development draft. The development draft is the working version of the website. It is composed of all the pages of the website, and includes active navigation links, animation, database driven pages, calculation, validation, and functionality. It also includes any administration functions for the content management of the website. The development draft provides a representation of the layout and the functions of the website. The development draft should be a representation of what the website will look like and how it will function when it is live. The development draft approval process involves detailed testing of the website. The IC reviews the development draft, documents any issues, presents the development draft to the client, enters required changes in the issue resolution section, and has the client sign the development draft approval form.
[0087] In step 1050 , the IC secures client approval of any change control guidelines. The change control documents the new client requirements after the client has signed a contract and the website has already been submitted for production. In this case, the IC maps the changes on the website plan, creates page information sheets, defines database data elements, and transmits all change control documents to the host.
[0088] Screen Shots. FIGS. 27 - 43 are screen shots illustrating the building phase, in an embodiment of the present invention. In alternative embodiments, the screen shots can be used in other phases of the invention. For example, FIGS. 41 - 43 are on-line accounting-related screen shots that can be used during the building phase, as well as other phases of the present invention.
[0089] Testing Phase
[0090] [0090]FIG. 11 is a flowchart illustrating testing phase 220 , according to an embodiment of the present invention. The testing phase is designed to insure a quality solution, emphasizing quality control and client involvement. In step 1105 , the IC tests the development draft of the website. The development draft is the working version of the website after coding and programming. Issues are noted in the issues tracking and reviewed by the host, with a subsequent development draft being created. Testing includes unit testing (verifies that all individual website functions perform), integration testing (verifies that functions or applications interface), compatibility testing (verifies website can be viewed and accessed by large majority of public), system testing (verifies client's hardware, software, and networking components support the website), security testing (verifies website is immune to unauthorized attempts to access it), error message testing (verifies website properly notifies the user of any errors), volume/stress testing (verifies weak points under varying workloads), destructive testing (verifies how the website responds to unusual or unexpected situations), and performance testing (verifies how the website measures against service-level requirements). In step 1110 , the client tests the development draft to verify that all business functions from the client's point of view are operating correctly. Issues are noted in the issues tracking and reviewed by the host, with a subsequent development draft being created. Once the client is satisfied with the development draft, the client signs a final approval form.
[0091] In an alternate embodiment of the present invention, the host implements technical testing standards that have been tested extensively by ICs and clients for usability and other desired features.
[0092] Launching Phase
[0093] [0093]FIG. 12 is a flowchart illustrating launch phase 225 , according to an embodiment of the present invention. During the launching phase, the website is placed live on the Internet and the IC and the client work closely to ensure the website's success as a true business solution.
[0094] In step 1210 , the IC reviews the client's level of connectivity and the systems configuration. If needed, a recommendation for an Internet service provider (ISP) and a systems consultant is provided.
[0095] In step 1215 , the website is activated, which is the process of making the website available for public view on the Internet. The process involves many steps and includes the movement of files between servers and directories. The IC ensures that the domain name resides on the host's server, completes all sections of the website online request form, and reviews website functions.
[0096] In step 1220 , the website is populated by the production data. Many websites include databases and content client side interfaces that store data. In most cases, these were built using a sub-set of the data that will be available on the website when it is online. In these cases, the remaining data is populated after the website is launched. In this process, the appropriate text and images, database tables are populated. In addition all test functions associated with each page are completed.
[0097] In step 1225 , the web site is registered with search engines. One of the key ways to drive targeted traffic is to ensure that the website is ranked high within search engine listings. The client should be consulted to discuss search engine strategies. The impact and optimization of the search engines are discussed, and existing traffic reports are reviewed. Then the website should be registered with the major search engines, and community and industry-specific search engines and hub-websites. The registration efforts are documented for the client's records.
[0098] In step 1230 , client training is conducted so that the client becomes familiar with the website's inner-workings and is further invested in the website's success. In addition, topics of interest to the client are discussed.
[0099] In step 1235 , marketing activities are performed. These include conducting a marketing business analysis, reviewing a client's collateral material, and considering: online and offline marketing options (e.g, email marketing, traditional direct mail, traditional print, radio and television advertising), a web warming party, press releases about the website, banner advertising and a referral program.
[0100] Managing Results Phase
[0101] [0101]FIG. 13 is a flowchart illustrating managing results phase 230 , according to an embodiment of the present invention. The managing results phase is designed to provide after-launch client management and services that ensure client satisfaction while driving more business for the IC and host. In step 1305 , principles of client management are applied. These principles are applied throughout the process 200 , but are particularly important during the manage results phase when the client is most sensitive to the value of what they have purchased. These principles include educating the client, setting and meeting expectations, and staying in regular contact with the client
[0102] In step 1310 , the IC and the client discuss the website's server report. The client is given the option of a standard (no access to website traffic analysis) or premium web-hosting option (includes access to website traffic analysis). If the client selects the premium option, a service such as that provided by Urchin Software Corp. can be used to track data on the website.
[0103] In step 1315 , the website is enhanced, if needed. Internet technologies and the global market are in constant change, and thus the client is given the option of upgrading. If an upgrade is desired, a subsequent business analysis is run, and the process 200 begins again.
[0104] In step 1320 , the client is queried about the return on investment. Based upon previously agree upon criteria, the IC polls the client about the website's performance and the client's satisfaction.
[0105] In step 1325 , the client is surveyed. Assessment and feedback are essential elements for continuous improvement. Documenting client feedback allows the host and IC to evaluate the business. The survey asks for feedback, including, but not limited to, feedback about the IC, the client's experience, the process, and the client's satisfaction with their Internet solution.
[0106] In step 1330 , a referral program is set up. The IC and client agree on a referral program. The IC agrees to provide compensation (e.g., pay a preset sum, provide client credit) for every referral that results in a signed contract. This gives the client added incentive to work with the host and IC in the future.
[0107] Conclusion
[0108] The present invention is described in terms of the above embodiments. This is for convenience only and is not intended to limit the application of the present invention. In fact, after reading the description of the present invention, it will be apparent to one skilled in the relevant art(s) how to implement the present invention in alternative embodiments.
[0109] In addition, it should be understood that FIGS. 1 - 13 described above, which highlight the functionality and advantages of the present invention, are presented for example purposes only. The architecture of the present invention is sufficiently flexible and configurable, such that it may be utilized in ways other than that shown in FIGS. 1 - 13 .
[0110] Furthermore, it should be understood that the screens shown herein, which highlight the functionality of the present invention, are presented for example purposes only. The software architecture (and thus, the screens) of the present invention are sufficiently flexible and configurable such that users may navigate through the system and method in a manner other than those shown in the screen shots.
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A system and method for delivering specialized business solutions is provided that includes six phases. The first phase is the business analysis phase during which an Internet consultant (IC) and/or host establishes rapport with a prospective client and creates an Internet business strategy. The second phase is the functional design phase during which the IC gathers the client's information to create a network website. The third phase is the building phase of the website during which coding and database integration for the website are produced in accordance with the functional design phase. The fourth phase is the testing phase during which the functional requirements of the website are tested. The fifth phase is the launching phase which places the website live on a server and registers the website. The sixth phase is the managing phase during which the IC and client meet at regular intervals to review website issues.
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The U.S. Government has rights in this invention pursuant to Contract Nos. DAAK10-84-0169 and DAAA21-88-C-0197 awarded by the Department of the Army.
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates to high strength-high density uranium alloys; and more particularly to ingot cast uranium-titanium-hafnium ternary metal alloys having enhanced mechanical properties compared with uranium-titanium binary metal alloys.
2. Brief Description of the Prior Art
The need for high density ballistic alloys of improved strength and ductility has long been recognized. Uranium, with a density of 19.05 g/cm 3 , is a well known candidate material for application in ballistic penetrator cores. Pure uranium, however, has a relatively low tensile strength (approximately 30 ksi). As a result, extensive efforts have been made to increase the tensile strength of uranium alloys while maintaining useful ductility. The results of these efforts culminated in the development of uranium-3/4Ti(wt %) alloy. Mechanical and ballistic properties of that alloy are described in the National Materials Advisory Board Report NMAB-350 (1980). This report, while recommending the use of U-3/4Ti for ballistic penetrator cores, also notes that improvement in mechanical properties must be made to address current and future counter threats in armor technology.
Typically, uranium-titanium metal alloys are cast into ingots and subsequently thermomechanically worked into plate or rod stock via techniques such as rolling or extrusion. As a final step, the alloys are given a high temperature anneal, typically at 800° C., causing the room temperature (orthorhombic) crystal structure of uranium to transform into the high temperature γ (bcc) crystal structure. This transformation results in solutionization of the titanium into the uranium lattice. The alloys are then strongly quenched (at quenching rates greater than 100° C./sec) to room temperature, freezing the titanium into solution. Since titanium is not normally soluble in the room temperature alpha phase, a metastable martensitic variant, denoted α a ' is formed to accommodate the supersaturated titanium.
The strengthening mechanisms in uranium-titanium alloys have been summarized by Eckelmeyer in "Diffusional Transformation, Strengthening Mechanisms, and Mechanical Properties of Uranium Alloys", from Metallurgical Technology of Uranium and Uranium Alloys (1981), page 129. The strength of uranium-titanium is attributable to several components. Primary strengthening arises from solid solution strengthening resulting from titanium supersaturation in the martensite. This supersaturation is also the basis for a precipitation hardening mechanism, by way of which aging at temperatures at or near 350° C. causes formation of very fine precursors to the U 2 Ti phase. As aging time continues, the volume fraction of precipitates increases, causing the strength to improve and the ductility to decrease. Ultimately, a peak in the hardness occurs beyond which both strength and ductility decrease.
It has been well documented that both strength and ductility of uranium-titanium alloys is strongly dependent on the titanium concentration. Indeed, Koger and Hemperly, Y-DA-6665, Union Carbide Corp., Oak Ridge, Tenn., (1976) have demonstrated a threefold drop in tensile elongation as the titanium content was increased from 0.7 to 0.8(wt) %. Thus, a practical limit to strengthening by increasing titanium concentration is reached due to a rapid decay of tensile elongation, a measure of ductility.
SUMMARY OF THE INVENTION
The invention provides a high density-high strength uranium base alloy having, in combination, increased strength and tensile elongation as compared with U-3/4Ti. Such a combination of increased tensile strength and elongation is accomplished by applying conventional ingot processing techniques to uranium-titanium alloys that have been modified by addition of hafnium in the range of 0 to 2 (wt) %. Further increase in hafnium content (i.e. to 5 wt % Hf) show greater strength improvement, however, this level results in decreased tensile elongation.
Hafnium has a moderately high density (approximately 13.3 g/cm 3 ), with the result that the strength increase due the hafnium addition is obtained with minimal density loss. The ternary U-3/4Ti-1.0Hf alloy, for example, has a measured density of 18.3 g/cm 3 compared with 18.6 g/cm 3 for U-3/4Ti.
It is probable that the addition of hafnium to U-3/4Ti accomplishes the strength increase by the mechanism of solid solution strengthening. The retention of hafnium in the α a ' martensitic solid solution is, in part, due to the lack of a uranium-hafnium intermetallic. Titanium and zirconium, the two other Group IVB elements, form U 2 Ti and U 2 Zr, respectively. The absence of a hafnium intermetallic thus allows more solute (i.e. hafnium) to be added without the excess precipitation of an intermetallic phase which could lower ductility.
This is important since Eckelmeyer and Zanner, J. of Nuc. Mat., 67, pp. 33-41, (1977) have demonstrated that excess U 2 Ti precipitation during the γ quench is deleterious to ductility. The retention of hafnium supersaturation during the γ quench is thus one of the factors responsible for the excellent tensile elongation.
The uranium-titanium-hafnium ternary alloys are also heat treatable in the same manner as the binary uranium-titanium alloys. In both cases, precipitation occurring in the supersaturated α a ' (martensite) results in an increase in hardness.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood and further advantages will become apparent when reference is made to the following detailed description of the preferred embodiment of the invention and the accompanying drawings, in which:
FIGS. 1a and 1b are optical micrographs of as-solutionized U-3/4Ti-1.0Hf and U-3/4Ti, respectively, the micrographs revealing an essentially identical microstructure consisting of lenticular martensite (α a ') with some decomposed α+U 2 Ti (grey phase);
FIGS. 2a, 2b, and 2c are plots of the 0.2% yield strength, ultimate tensile strength, and tensile elongation of as-solutionized U-3/4Ti-Hf x ternary alloys as a function of hafnium content (in wt %), the alloys having been solutionized in vacuum at 800° C. for 4 hrs and water quenched;
FIG. 3 is a graph showing hardness vs. aging time at 385° C., for one of the alloys shown in FIG. 2;
FIGS. 4a, 4b, and 4c are plots of the 0.2% yield strength, ultimate tensile strength, and tensile elongation for alloys of FIG. 2 that have when aged for 4 hrs at 385° C.; and
FIG. 5 is a graph showing 0.2% tensile yield strength as a function of 0.2% compressive yield strength for the alloy U-3/4Ti-1.0Hf and U-3/4Ti, the alloy U-3/4Ti-1.0Hf having been aged at 385° C. for 4 hrs and the alloy U-3/4Ti having been aged at varying aging temperatures, the data for U-3/4Ti taken from Zabielski, MTL-TR-88-29, 1988.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention provides a high strength uranium base alloy, consisting essentially of the formula U bal -Ti x Hf y wherein x ranges from about 0.5 to 1.0 wt % and Y ranges from about 0.1 to 5.0 wt %.
The alloys are a ternary modification to the binary alloy system uranium-titanium in which the titanium is added to form a martensitic variant (denoted α a ') of the orthorhombic (γ) uranium lattice. The martensite is supersaturated with titanium forming a substitutional solid solution. As a solid solution, a substantial strength increase is obtained, as compared with unalloyed uranium. The supersaturation makes the alloy especially suited to undergo a precipitation hardening reaction. This reaction occurs in the range of about 200°-400° C.
Useful solid solution strengthening in uranium-titanium alloys is normally limited to having Ti content compositions ranging to 1.0 wt %, due to a strong decrease in ductility for alloys containing beyond approximately 0.8 wt % Ti. Alloys of the invention overcome this problem by the ternary addition of hafnium. The element hafnium forms no intermetallic phases with uranium and essentially extends the useful range over which the alloy can be subjected to solid solution strengthening without deleterious loss in ductility.
The improvement in 0.2% tensile yield strength resulting from the ternary hafnium addition is also seen in the 0.2% compressive yield strength. The ternary hafnium addition accomplishes this strengthening without detrimental reduction in density, due to hafnium's relatively high density of 13.3 g/cm 3 . The combination of high strength, good ductility, and high density makes the U bal -Ti x -Hf y ternary alloys of the present invention ideal candidates for ballistic applications.
The following examples are presented to provide a more complete understanding of the invention. The specific techniques, conditions, materials, proportions and reported data set forth to illustrate the principles and practice of the invention are exemplary and should not be construed as limiting the scope of the invention.
EXAMPLES 1-4
Alloys of the invention having the compositions listed in Table I below were prepared using conventional ingot casting techniques. The alloys were melted under inert atmosphere at approximately 1300° C. and cast into billet form. Subsequently, the cooled billets were extruded at 600° C. into rod form.
TABLE I______________________________________ AlloySample No. Composition (wt %)______________________________________1 U-3/4Ti-0.5Hf2 U-3/4Ti-1.0Hf3 U-3/4Ti-3.0Hf4 U-3/4Ti-5.0Hf______________________________________
EXAMPLE 5
FIGS. 1a and 1b show optical micrographs of as-solutionized U-3/4Ti-1.0Hf along side U-3/4Ti, for reference. Both micrographs reveal an essentially identical microstructure of lenticular martensite (α a ') with some decomposed α+U 2 Ti (grey phase). The presence of a substantially identical microstructure for the alloys when subjected to a given thermal treatment, indicates that the hafnium addition did not adversely affect the transformation behavior. From this it will be seen that the benefits of the ternary alloys may be realized without altering thermal processing history conventionally applied to the binary U-Ti alloys.
EXAMPLE 6
Alloys in Examples 1-4 were vacuum solutionized at 800° C. for 4 hrs and water quenched. The alloys were then machined into subscale tensile specimens with a 0.16 inch gauge diameter and 0.64 inch gauge length and tensile tested at room temperature. The results based on an average of three tensile tests, are listed in Table II. For comparison, the as-solutionized tensile data for U-3/4Ti are listed. The effect of hafnium content on yield strength, ultimate tensile strength, and tensile elongation is further illustrated in FIGS. 2a, 2b, and 2c, which are plots of the data listed in Table II.
TABLE II______________________________________ 0.2% Ultimate % Elonga- % Yield Tensile tion to ReductionComposition Strength Strength Fracture of Area______________________________________U-3/4Ti 100 200 23 34U-3/4Ti-0.5Hf 100 200 28 52U-3/4Ti-1.0Hf* 134 235 20 --U-3/4Ti-3.0Hf 146 247 13 25U-3/4Ti-5.0Hf -- -- -- --______________________________________ *Rolled plate rather than extruded bar
The tensile properties set forth in Table II and FIGS. 2a, 2b, and 2c show that the yield and ultimate strength increase with hafnium content. The tensile elongation, in contrast, appears to peak at 0.5% Hf. It is notable that the alloy U-3/4Ti-0.5Hf shows improbed elongation and reduction of area while having the same strength as U-3/4TI. The alloy U-3/4Ti-1.0Hf shows improved strength over U-3/4Ti while having approximately the same tensile elongation.
This example illustrates the importance of optimizing the amount of hafnium to provide increased strength while maintaining ductility. The presence of hafnium in the amounts called for by the present invention extends the amount of solid solution strengthening obtainable in this alloy without loss in ductility. Advantageously, hafnium additions allow the aggregate combination of tensile strength and tensile ductility to increase.
EXAMPLE 7
This example illustrates that the ternary U-3/4Ti-Hf alloys are amenable to precipitation hardening in a manner similar to U-3/4Ti. Hardness samples were prepared by solutionizing specimens in the manner described in Example 6. The samples were then aged for various times in a salt bath at 385° C. FIG. 3 plots the resulting hardness as a function of aging time. The U-3/4Ti-1.0Hf alloy shows a hardening response, indicating that precipitation strengthening found in the binary U-Ti alloys is retained in the ternary U-Ti-Hf alloys.
EXAMPLE 8
The improved strength-ductility combination in the U-Ti x Hf y alloys, as compared with the binary U-Ti alloys, occurs not only in the as-Solutionized condition but also in the aged condition. This is illustrated by performing tensile tests in a manner identical to that of Example 5. In this example, however, an aging treatment of 385° C. for 4 hrs was added after the solutionization. The resulting data is listed in Table III, along with that of identically aged U-3/4Ti for comparison.
The data reveal that the 385° C. aged ternary U-3/4Ti-Hf y alloys show higher strength than U-3/4Ti as was the case with the unaged material. Comparison of Table III and Table II also indicates that the aging caused an average 20 ksi yield strength improvement for any given composition. This further illustrates the precipitation hardening behavior shown by Example 7, i.e. that the strength of the ternary U-3/4Ti-Hf alloys increases in a manner similar to U-3/4Ti. The variation in tensile properties of the aged material as a function of hafnium content is further illustrated by FIGS. 4a, 4b, and 4c. The behavior is similar to that observed in FIGS. 2a, 2b, and 2c.
TABLE III______________________________________ 0.2% Ultimate % Elonga- % Yield Tensile tion to ReductionComposition Strength Strength Fracture of Area______________________________________U-3/4Ti 120 201 22 24U-3/4Ti-0.5Hf 120 216 25 47U-3/4Ti-1.0Hf 130 238 21 35U-3/4Ti-1.0Hf* 146 238 21 29U-3/4Ti-3.0Hf 160 262 14 18U-3/4Ti-5.0Hf 244 287 2 --______________________________________ *Plate stock rather than extruded rod
EXAMPLE 9
This example illustrates that the tensile strength improvement observed from the addition of hafnium is also found in the compressive strength. Compressive samples 1/4 inch in diameter and 3/4 inch height were machined from the U-3/4Ti-1.0Hf alloy. The heat treatment was identical to that of Example 8. FIG. 5 plots the compressive strength reported for 833 specification U-3/4Ti reported by C. V. Zabielski, MTL TR 88-29, U.S. Army Materials Technology Laboratory, Watertown, Mass., (1988). The ternary U-3/4Ti-1.0Hf alloy shows higher tensile and comprssive strength than those reported for the binary alloy. This compressive strength improvement arises without a loss in ductility as was described in Examples 6 and 8.
Having thus described the invention in rather full detail, it will be understood that these details need not be strictly adhered to but that various changes and modification may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.
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A uranium-base alloy consists essentially of the formula U bal -Ti x -Hf y , where "x" ranges from about 0.5 to 1.0 and "y" ranges from about 0.5 to 5.0. The alloy exhibits high strength, good ductility and high density and is especially suited for use in ballistic penetrator cores.
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BACKGROUND OF THE INVENTION
Maximum power can only be obtained from an internal combustion engine if the ignition timing is correct. Any timing fluctuation between cylinders (spark scatter) or timing fluctuation at a single cylinder (spark jitter) reduces the power output of the engine. Common causes of timing fluctuation are the flexing and end play of the engine camshaft; distributor gas "play"; distributor point cam inaccuracies; distributor point bounce and wear; timing chain and gear wear; and false ignition triggering. These inaccuracies are particularly important in high performance, high RPM engines, because these engines normally utilize the maximum advance possible before pre-ignition occurs. Precise ignition timing allows this advance limit to be more closely approached.
Ordinary prior distributors commonly exhibit timing inaccuracies of several degrees, particularly at high RPM. Point bounce has been eliminated through the use of magnetic pulse distributors and the points cam has been eliminated, but the remaining causes of ignition timing inaccuracies are still present and create significant timing errors.
An effort to solve these problems and produce precision timing pulses haa been undertaken by several manufacturers. The solution is general has been the substitution or addition of a crankshaft trigger wheel. The wheel is usually attached to the engine crankshaft directly by bolting it to the engine's harmonic balancer. The wheel of the prior art is usually made of aluminum with four ferrous steel tabs located 90° apart (for an eight cylinder engine) on the wheel outer perimeter. Others have employed ferrous steel with teeth or notches radially spaced around the perimeter. A magnetic pickup is located in a selected fixed position in close proximity to the tabs, teeth, or notches so that a suitable electrical pulse is generated in the magnetic pickup as the tab passes near the pickup during crankshaft rotation. The resultant pulses are used to trigger an electronic ignition system which in turn produces the high voltage ignition pulses used to ignite the combustion mixture. The prior art crank trigger wheels provide a substantially higher degree of timing accuracy than conventional distributor system; however, they still possess several negative characteristics. The most serious of these is the lack of sufficient noise immunity in order to prevent false ignition triggering, a major cause of drastic ignition timing inaccuracy. Another shortcoming of crankshaft trigger wheels of the prior art is the two piece construction utilized with aluminum wheels. These wheels use steel tabs or pins as stated above which can loosen and therefore create timing jitter or become completely separated from the wheel.
SUMMARY OF THE INVENTION
The present invention provides a crankshaft trigger wheel made from ferrous metal shaped to produce a high electrical noise immunity wave form when combined with a conventional magnetic pickup.
More specifically, this invention provides a trigger wheel which has an outer, circumferentially extending surface interrupted by the intersection of corners, with the corners being defined by two adjacent arcs, with each arc having a radius greater than the radius of an imaginary circle described by rotating the wheel about its central axis. The intersection of the arcs occur on the imaginary circle. This provides the outer peripheral surface of the wheel with a varying radius deviation, with 0.125" maximum deviation being preferred. The wheel of the present invention can be substituted for the harmonic balancer located on the end of the crankshaft of an internal combustion engine.
Accordingly, a primary object of the present invention is the provision of a crankshaft trigger wheel shaped to produce a high electrical noise immunity wave form.
Another object of the invention is the provision of a trigger wheel in combination with a conventional magnetic pickup of an ignition system for an internal combustion engine.
A further object of the present invention is to disclose and provide a crankshaft trigger wheel for providing a signal by which a high tension electrical voltage is developed for the spark plug of an internal combustion engine.
A still further object of the present invention is to provide a wheel device having projections thereon in combination with a magnetic pickup for providing a signal having high electrical noise immunity.
Another and still further object of the present invention is the provision of a combination crankshaft, harmonic balancer, and trigger wheel for use in an ignition system which improves the ignition timing in an internal combustion engine.
The above objects are attained in accordance with the present invention by the provision of apparatus fabricated in a manner substantially as described in the above abstract and summary.
These and various other objects and advantages of the invention will become readily apparent to those skilled in the art upon reading the following detailed description and claims and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a part schematical, part diagrammatical broken view of an ignition system together with an internal combustion engine wherein the system includes a crankshaft trigger wheel made in accordance with the present invention;
FIG. 2 is a fragmented, enlarged, side elevational view of a modification of the apparatus disclosed in FIG. 1;
FIG. 3 is a plan view of a crankshaft trigger wheel made in accordance with the present invention;
FIG. 4 is a side view of the apparatus disclosed in FIG. 3;
FIG. 5 is a wave form made by the apparatus disclosed in the foregoing figures;
FIG. 6 is a wave form generated according to prior art expedients;
FIG. 7 is a curve illustrating the effect of changing one variable respective to the present invention;
FIG. 8 is a diagrammatical illustration related to the fabrication of the present invention;
FIG. 9 is a modification of the apparatus disclosed in FIG. 3;
FIG. 10 is a 2 of modification 2 apparatus in FIG. 3;
FIG. 11 is a side view of the apparatus disclosed in FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 discloses a combination 10 comprised of an ignition system and an internal combustion engine. An ignition system 12 is connected to the internal combustion engine 14 in such a manner that the spark plugs 15 are fired in proper sequential order. A harmonic balancer 16 is connected to the illustrated crankshaft of the engine, and the usual pulley 17 is spaced from the balancer by a crankshaft trigger wheel 18 made in accordance with the present invention. Accordingly, the trigger wheel 18 is concentrically arranged respective to the shaft, balancer, and pulley assembly.
A magnetic pickup 20 is mounted at 21 in slightly spaced relation from the outer peripheral surface of the wheel 18 and thereby provides an improved electrical signal for the multiple strike discharge circuitry 22, hereinafter referred to as "MSD".
The MSD circuitry 22 preferably is made in accordance with U.S. Pat. No. 3,926,165.
The apparatus 22 is connected to a suitable source S of current and the output 24 thereof is connected to a conventional ignition coil 25 and distributor 26, which in turn conducts high voltage current from 24 to each of the spark plugs 15.
In the illustration of FIG. 2, the crankshaft, harmonic balancer, and trigger wheel have been combined into a unitary device in the form of the illustrated trigger wheel 118. This expedient enables the engine manufacturer to advantageously equip the internal combustion engine 14 with the trigger wheel of the present invention at the factory rather than retro-fitting the engine at some subsequent date.
FIG. 3 discloses a plan view of either of the trigger wheels disclosed in the foregoing figures. As seen in FIG. 3, the wheel rotates to describe an imaginary circle having a diameter 28. Arcs 30 form a marginal, circumferentially extending periphery of the wheel and are described by a radius which is greater than the radius which describes outside diameter 28. The adjacency of arcs 30 describe a corner 32 which could aslo be termed an intersection or protrusion. Corners 32 are radially spaced 90° from one another for a four cycle, eight cylinder engine, while 45° from each corner there is seen a point of maximum deviation 34 of of the wheel surface.
Apertures 36 provide a bolt circle by which the centrally apertured trigger wheel can be securely affixed to the marginal end of the crankshaft.
FIG. 5 discloses a wave form which describes the output voltage of the magnetic pickup 20. Numeral 44 indicates a position 34 which is 45° from a corner 32, while numerals 46 and 48 indicate the magnitude of the voltage of the wave form.
In the prior art illustration of FIG. 6, it will be noted that there is a substantial amount of time 50 during which the output voltage of a magnetic pickup is zero. Numeral 52 indicates the time during which the output voltage is other than zero.
FIG. 7 discloses a curve 38 which relates spacing in inches to noise immunity shown to the left of the figure. In particular, FIG. 7 discloses the effect of varying the deviation 34 with respect to noise immunity.
FIG. 8 discloses one means by which a trigger wheel of the present invention can be fabricated. As seen in FIG. 8, a circular metal plate 18' is provided, having a center 134 and a radius r 1 . d is the maximum radius deviation from a circle desired in the trigger wheel. x is the distance from the center of the circle from which one side of the wheel shape is defined. b is the side opposite, while c is the side adjacent of adjacent of a 90° triangle having a hypotenuse r 2 . The angle theta depends upon the number of cylinders associated with the internal combustion engine as well as the number of strokes per cycle.
FIG. 9 discloses a trigger wheel for a six cylinder, four stroke engine wherein the corners are placed 120° apart. The radius deviation is illustrated between numerals 28 and 30.
FIG. 10 illustrates still another modification of the present invention wherein protrusions 50 have been included at the corners or intersect of the adjacent arcs 28. Accordingly, the protrusions 50 provide for improved engine starting characteristics while at the same time the low noise immunity obtained from the deviation 28-30 is realized by this embodiment of the invention.
OPERATION
The purpose of this invention is to provide a crankshaft trigger wheel made from ferrous metal. The wheel is uniquely shaped to produce an unexpected high electrical noise immunity waveform when combined with a conventional magnetic pickup. The wheel for an eight cylinder engine is shown in the drawing in FIGS. 3 and 4.
As seen in FIGS. 3 and 5, as the surface of the wheel gets closer to or further away from the magnetic pickup during wheel rotation, the pickup magnetic field is disturbed, thereby establishing a magnetic flux which results in a voltage. The flux is virtually continuous since the distance from the magnetic pickup to the surface of the wheel is continuously varying. The only time a zero voltage is produced is when the direction of the flux is reversed. This occurs at eight points around the wheel as indicated in FIG. 3. The maximum flux is created when the "corners" of the wheel have rotated closest to the magnetic pickup. As a corner passes the magnetic pickup the direction of flux is reversed yielding a voltage of opposite polarity. In FIG. 5, the amplitude 46, 48 of this voltage is extended with time since flux is still present due to the gradual, continuously changing proximity of the wheel'surface in relationship to the magnetic pickup. As the wheel rotates past the position 45° from the corner the flux direction reverses and creates a voltage which is opposite in polarity. The voltage amplitude increases until the next corner passes the magnetic pickup and the flux is again reversed. This process continues as the wheel rotates. The resultant waveform possesses high noise immunity since electrical noise normally capable of false triggering an ignition system becomes an integral part of the basic high level signal and therefore is not sufficiently distinguished to establish a separate trigger signal.
By comparison, a typical conventional crank trigger wheel waveform is shown in FIG. 6. The flux is abrupt produced and very little noise immunity is exhibited. During the zero voltage time any electrical noise with sufficient amplitude (typically 0.3v or greater) can false trigger the controlled ignition.
The geometrical technique for determining the crank-shaft trigger wheel dimensions for a given wheel thickness, maximum diameter and maximum radius deviation from a circle is shown in FIG. 8. The wheel thickness was not found to be a critical parameter. Several thicknesses were found to exhibit substantially identical characteristics. The wheel maximum diameter dimension (2r 1 ) should be large enough to easily obtain geometrical accuracy, thereby minimizing the effect of construction errors. The maximum radius deviation from a circle (dimension d) is selected to produce the desired noise immunity. For a given radius (r 1 ), as the dimension d is decreased, the noise immunity increases until finally a change to no noise immunity is reached due to the wheel shape become a circle. This relationship is shown graphically in FIG. 7. The dimension d of approximately 1/8 inch was found to be satisfactory because it provided high noise immunity, retention of a low RPM capability, and the distance between the wheel corners is sufficiently spaced from the magnetic pickup to render the surface texture of the wheel non-critical.
Irregularities on the the wheel surface can create self induced electrical noise spikes if the outer wheel surface is positioned too close to the magnetic pickup during rotation. This is especially so in the region mid-way between two wheel corners where the noise immunity is at a minimum value.
The following derivations show that the wheel shape is defined by dimension "d" and "r 1 ".
Let r.sub.1 = 1/2 the maximum diameter of the wheel
Let d= maximum radius deviation from a circle
Then r.sub.2.sup.2 = b.sup.2 + c.sup.2
r.sub.2 = √ b.sup.2 + c.sup.2
Also r.sub.2 = r.sub.1 - d+ x
And b= x+ r.sub.1 cosθ = x+ r.sub.1 cos 45° for eight cylinders.
Or x= b-r.sub.1 cosθ
And c= r.sub.1 cos 45°
∴ √ b.sup.2 + c.sup.2 = r.sub.1 - d + x
Let y== r.sub.1 - d
Then b.sup.2 + c.sup.2 = (y + x).sup.2
b.sup.2 + c.sup.2 = y.sup.2 + 2xy+ x.sup.2
b+ c.sup.2 = (r.sub.1 - d).sup.2 + 2x(r.sub.1 - d)+ 2x.sup.2 = r.sub.1.sup.2 - 2r.sub.1 d+ d.sup.2 + 2xr.sub.1 - 2xd+ x.sup.2
b.sup.2 + (r.sub.1 cos 45°).sup.2 = r.sub.1.sup.2 - 2r.sub.1.sup.d + d.sup.2 +2r.sub.1 (b - r.sub.1 cos 45°) - 2d (b- r.sub.1 cos 45°)+ b.sup.2 - 2br.sub.1 cos 45° + (r.sub.1 cos 45°).sup.2
(r.sub.1 cos 45°).sup.2 = r.sub.1.sup.2 - 2r.sub.1 d+ d.sup.2 + 2r.sub.1 b- 2r.sub.1.sup.2 cos 45° - 2db+ 2dr.sub.1 cos 45° - 2br.sub.1 cos 45° + (r.sub.1 cos 45°).sup.2
- 2r.sub.1 b+ 2db+ 2br.sub.1 cos 45° = r.sub.1.sup.2 - 2r.sub.1 d+ d.sup.2 - 2r.sub.1.sup.2 cos 45° +2dr.sub.1 cos 45° + (r.sub.1 cos 45°).sup.2 - (r.sub.1 cos 45°).sup.2 ##EQU1##
solving for x and r.sub.2,
x= b- r.sub.1 cos 45°
r.sub.2 = r.sub.1 - d+ x= r.sub.1 - d+ b- r.sub.1 cos 45°
As r 2 is rotated about the point defined by the distance x from the center of the circle one side of the wheel shape is defined. The other three sides are defined by relocating the point defined by the distance x from the circle in 90° increments and rotating r 2 about each point.
The maximum radial deviation can vary from a value almost approaching a circle up to a value almost approaching the radius of a wheel; but for practical purposes, Aplicant prefers to limit the maximum radial deviation to a value between the limits of 0.02 to 0.9 inches. The value of 0.02 is selected in accordance with the curve of FIG. 7. The value of 0.9 is selected because reasonable noise immunity is achieved within this limit.
The six cylinder wheel of FIG. 9 contains three corners. This produces a trigger pulse every 120° of crankshaft rotation instead of every 90° as in the before mentioned eight cylinder engine.
The four cylinder wheel (not shown) contains two corners. This produces a trigger pulse every 180° of crankshaft rotation.
FIGS. 10 and 11 disclose a wheel which is advantageously used when a lower RPM triggering capability is desired. Small ferrous metal tabs 50 are included at each corner. The tab positions establish the triggering points and the gradually varying wheel radius 30 between the corners increases the noise immunity by adding to the basic magnetic pickup output signal created by the tabs.
The present invention can be applied to two or four stroke engines using any number of cylinders. Additional applications include all rotating mechanisms where high noise immunity timing or pulse detection is desired.
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An improved crankshaft trigger wheel for use in an ignition system for an internal combustion engine. The configuration of the trigger wheel provides a high degree of electrical noise immunity, provides a single piece construction which has the dual function of a trigger wheel as well as an engine harmonic balancer. The wheel is made into a configuration which is easily shaped during manufacture, and provides a wheel shape which produces a higher degree of timing accuracy. The wheel of the present invention has an outer, circumferentially extending surface interrupted by corners, with the corners being defined by two adjacent arcs, wherein each arc has a radius which is greater than the radius of a circle described by the rotating wheel.
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FIELD OF THE INVENTION
This invention relates to a vacuum-type article holder and to methods of supportively retaining articles by forces generated by a vacuum. This invention advantageously applies to an article holder for and to methods of supportively retaining articles which are fragile, such as seimconductor wafers. Such wafers are comparatively thin with respect to their size and are therefore likely to become damaged through improper handling techniques.
BACKGROUND OF THE INVENTION
The invention is particularly described in relationship to a vacuum-type wafer holder for holding semiconductor wafers in an electrolytic treatment operation. However, the described details of the invention in relationship to particular examples are to convey a full understanding of the features of the invention and are not intended to be limiting to the scope of the invention. Therefore, articles other than semiconductor wafers and handling processes other than electrolytic treatments are seen to be advantageously improved by the invention.
Semiconductor wafers are typically thin (20 mils) slices of single-crystal material which serves as the starting material for various types of semiconductor devices. In a series of production steps, a large number of small semiconductor circuits are formed within the body of such wafers. At the conclusion of the device-forming production steps, the wafers are cut into small chips, each chip being one of the semiconductor devices.
The production steps typically make use of high-resolution photolithographic processing techniques including electrolytic plating and etching steps. Handling the wafers throughout the various process steps is always of concern, in that defects introduced during any of the process steps reduce the yield of good chips from each wafer and thereby raise the cost of the remaining chips. It is, therefore, of utmost concern to minimize the introduction of manufacturing defects.
For example, the yield of good chips is likely to be affected by merely accidentally touching a wafer with bare hands or by contacting a wafer with handling tools in an unusual manner during any one of the various process steps. surface smudges on the wafers or depositions of dust particles on the surfaces of the wafers are typical causes of yield problems. Therefore, automated handling processes have been developed wherein contamination by smudges or dust particles has been minimized. These automated handling processes frequently involve the use of vacuum forces to retain the wafers.
As an example, U.S. Pat. No. 3,558,093 to H. F. Bok relates to a vacuum memory holding device of the type used as a tray for supporting a plurality of wafer-like objects in a spray-coating chamber. The holding device includes a vacuum chamber, one wall of which resiliently collapses against springs as the vacuum is generated in the chamber to hold the vaccum in the chamber.
Another example of a vacuum-operated work holding device is disclosed in U.S. Pat. No. 3,481,858 to H. A. Fromson. According to the Fromson patent, a workpiece to be subjected to an electrolytic operation is held by a suction cup. A vacuum passage terminating at the suction cup is normally closed by a spring-loaded valve and pin combination. When the vacuum cup is pressed against the surface of the article, the pin is pushed into contact with the article and the vacuum valve to the suction cup is opened. The pin also establishes electrical contact with the article which is electrically insulated from the ambient by the surrounding vacuum cup.
In the above-mentioned examples of vacuum holders, maintaining the planarity of the articles is of no concern. However, in processing semiconductor wafers into state-of-the-art integrated circuits, holding the wafers without disturbing their planarity has been recognized as being of significance in photolithographic exposure steps. U.S. Pat. No. 4,213,698 to V. T. Firtion et al. relating to apparatus and method for holding and planarizing thin workpieces, discusses the significance of maintaining the planarity of thin semiconductor wafers in pattern exposure operations.
The above-mentioned Firtion et al. patent discloses a wafer holder featuring a seat of a plurality of pin-like extensions from a baseplate. The ends of the extensions terminate in a plane, and a compressible seal surrounds the extensions. Thus, after a wafer is placed onto the seat, a vacuum is drawn in the space about the extensions. The wafer is drawn against the ends of the extensions and thereby becomes supported with a high degree of planarity. The relatively small support area between the extensions and the wafer minimize the possibility of dirt particles from becoming trapped between the supporting extensions and the wafer in that such dirt particles might disturb the planarity of the wafer.
It now appears that yield-reducing defects may be generated during process steps other than the pattern exposure operations when the wafers are held by vacuum in a manner which tends to induce a bow or other strain into the wafers. It appears, for example, highly advantageous to support the wafers with as little strain on the wafers as possible during all electrolytic treatments such as plating or etching.
SUMMARY OF THE INVENTION
In accordance with the invention, a vacuum-type holder for an article includes a housing which encloses at least one vaccum cavity. The vacuum cavity has at least one opening through a wall of the housing, such that the opening is located within the confines of a seat adapted to retain the article when a vacuum is drawn within the cavity. The cavity is adapted to be coupled to a vacuum. A structure is movably mounted within the cavity. The structure includes a provision for contacting and supporting the article through the at least one opening with a supporting force opposite and proportional to a retaining force acting on the article in response to the vacuum within the cavity.
BRIEF DESCRIPTION OF THE DRAWING
Various features and advantages of the invention are best understood when the following detailed description is read in reference to the appended drawing, wherein:
FIG. 1 is a pictorial representation of a wafer holder showing features of the present invention;
FIG. 2 is a sectional view of the wafer holder of FIG. 1 showing details of a vacuum cavity and a respective seat for one of the wafers with the pressure in the cavity being equal to that of the ambient;
FIG. 3 is a sectional view of the wafer holder of FIG. 1 showing details of a vacuum cavity in relationship to a respective wafer when a vacuum is established within the cavity; and
FIG. 4 shows an alternate embodiment of certain features of the invention.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown an article holder, specifically a wafer holder, designated generally by the numeral 10, which is described herein as a preferred embodiment of the invention. The wafer holder 10 has a body or housing 12, preferably of a material such as an acrylic or polyvinyl chloride. Such materials are electrical insulators and are inert to typical plating baths. A lower portion of the plate-shaped housing 12 features a plurality of cavities 14 of circular topography, slightly smaller in diameter than the diameter of wafers 16 which are to be seated and held in place over each of the respective cavities 14.
Without one of the wafers 16 in place over a corresponding one of the cavities 14, the cavity 14 is a circular cylindrical recess in the body 12 of the holder 10. For a vacuum to be drawn in the cavity, one of the wafers 16 needs to be placed over an opening 17 of the respective cavity 14.
Modifications may, of course, be made in various details of the structure without departure from the scope of the invention. For example, in the embodiment of FIG. 1, the cavities 14 are located in and defined by molded cavity members 20 which are preferably of a resilient, protecting and sealing material, such as silicone rubber. A plurality of the molded cavity members 20 are assembled into the holder 10 as shown in FIG. 1. FIG. 4 shows an alternate embodiment of a cavity wherein the cavities 14 are directly within the housing and a separate sealing member, such as an O-ring 21, is partially embedded into the housing. Locating pins 22, preferably of the same, inert material as the housing, are alternatively supplied, as shown in FIG. 4, to eatablish lateral boundaries of seats 23, such that the wafers 16 may be aligned more readily over the openings 17.
In reference to FIG. 2 showing a section through the holder 10 of FIG. 1, a vacuum suction duct 24 leads from each of the cavities 14 to a common manifold chamber 26 in an upper portion 27 of the housing 12. As becomes apparent from FIG. 1, the manifold chamber preferably extends substantially the length of the housing 12 as an elongate recess in the upper portion 27 of the housing 12. The recess is then closed off, as shown in FIG. 1, by a sealing cover plate 28 having a single vacuum line coupling 29, which in turn, is then coupled to a typical vacuum source 31.
Inasmuch as the articles, namely the wafers 16, which are placed onto the seats 23 are to be treated electrolytically, an electrical contact to the wafers 16 is preferably established to the backsides 32 of the wafers 16 which are the inner surfaces facing the cavities 14. As shown in FIG. 1, a contact element 36 is mounted on a pedestal 37 in the center of each of the cavities 14. In reference to FIGS. 1 and 2, an electrical, insulated lead 38 is routed from each of the cavities 14 to an electrical connector 39 at the top of the housing 12.
In a typical electrolytic treating operation such as, for example, a metal plating operation, the wafers 16 are placed onto the seats 23 and a vacuum is drawn in the cavities 14 to hold the wafers 16 in place and to establish electrical contact between the contact elements 36 and the wafers 16 (see FIG. 3). The holder 10 is then partially submersed in an electrolytic bath 40 of a plating tank 41, as shown in FIG. 3, to place the wafers 16 into an electrolytic treating circuit 42.
Particular features and advantages of the invention are best explained in reference to FIGS. 2 and 3. For example, a firm electrical contact between the contact element 36 and the adjacent surface 32 of the wafer 16 is highly desirable to reliably obtain an electrolytic treatment of predictable quality on an outer surface 47 of the wafer 16. However, to protect the wafer 16 from possibly becoming damaged while being loaded onto the seat 23, it is also desirable to recess the contact element 36 below a mounting surface 48 of the seat 23. In addition, it is desirable to minimize strain on the wafer during the electrolytic surface treatment. Such strain tends to occur when the vacuum is applied for holding the wafer and for urging it toward and into contact with the contact element 36.
FIG. 2 is a section through a representative one of the seats 23 and through the associated cavity 14 including the pedestal 37 and the contact element 36. As shown in FIG. 2, the pedestal 37 extends from an inner surface of a resiliently flexible diaphragmatic wall 51 through the cavity 14 toward the seat 23. Without a vacuum drawn in the cavity 14, the contact element 36 has its normal rest position below the mounting surface 48 of the seat 23, as shown in FIG. 2. Thus, when a wafer 16 is placed onto the seat 23 with some sliding motion to move it into a well-centered position over the cavity 14, the inner surface 32 of the wafer 16 (see also FIG. 3) is prevented from accidentally scraping across the contact element 36.
Once the wafer 16 is positioned on the seat 23, and a vacuum is drawn in the cavity 14, as shown in FIG. 3, the pressure differential across the wall 51 having a relatively greater pressure, as indicated by arrows 52, on the outside of the wall flexes the wall 51 and, hence, urges the pedestal 37 toward the seat 23 and urges thereby the contact element 36 firmly into contact with the adjacent, inner surface 32 of the wafer 16.
Referring particularly to FIG. 3, the wafer 16 is pulled by the vacuum toward the cavity 14 and into firm, sealing contact with the mounting surface 48 of the seat 23. It should be realized that in the absence of a support in the cavity 14, the wafer 16 would tend to become strained toward the cavity 14, such that the wafer 16 would assume a concave shape.
However, the contact element 36 pushes against the adjacent inner surface 32 of the wafer 16 and, hence, urges the wafer outward woth a force opposite to, and ideally only nominally less than, the inward pressing force on the wafer 16. As a result, the contact force between the contact element 36 and the adjacent surface 32 of the wafer 16 is positive and firm, while the supporting force by the contact element 36 at the same time balances out the inward force on the wafer 16, such that the planarity on the wafer is substantially preserved.
The magnitude of the supporting counterforce exerted against the wafer 16 by the contact element depends on the particular geometry of the pedestal and on that of the diaphragmatic wall 51. Referring to the geometry of the preferred embodiment shown in FIG. 2, a differential pressure force acting on the wall 51 within a circle indicated by the diameter `D`, namely in the area bounded by a knee 53 in the wall 51, is substantially equal to the total counterforce exerted against the inner surface 32 of the wafer 16. Since this supporting force is applied to the center of the wafer 16 and the periphery of the wafer is, of course, supported by the mounting surface 48 of the seat 23, only a comparatively narrow, annular region of the wafer 16 remains unsupported. As a result, wafers 16 when supported by the described structure of the wafer holder 10 show no discernible deviation from their flatness.
The preferred embodiment of FIGS. 1, 2 and 3, because of its structure is readily assembled and serviced. The molded cavity members 20 are unitary structures of resilient silicone rubber which are readily inserted into outer support apertures 57 of the housing 12. A ledge 58 about the periphery of each of the molded members 20 fits into a corresponding annular groove 59 in the respective support aperture 57 to securely retain the inserted portion thereon. A lower removable housing portion 60 facilitates the insertion of the cavity member 20 into the support apertures 57. The contact element 36 is preferably inserted into the pedestal 37 prior to the insertion of the cavity members 20. The contact elements 36 fit into appropriately provided recesses 61 in the pedestals 37, and insulated electrical leads or conductors 38 are inserted through central base openings 63 in the pedestals after the members have been inserted into the housing 12. Insulative jackets 64 of the conductors 38 when pushed into the base openings 63 seal these openings to prevent electrolytic fluids from contacting the conductors 38 or the contact elements 36 during subsequent usage of the wafer holder 10. A room temperature vulcanizing silicone rubber compound may be used in addition to seal the base openings 63 after the conductors 38 have been inserted therein.
An advantage of such unitary, molded members 20 is realized in the ease replacing the conductors 38 or even the molded members 20 as such, should they become contaminated or should the contact members 36 become corroded. Another advantage is that the molded members 20 can be replaced by molded members of different shapes or sizes, so that the wafer holder 10 can be used as a universal structure for holding wafers or other articles of various sizes and shapes. To adapt the wafer holder 10 to support wafers 16 of different diameter, the molded members 20 are removed from the housing 12 and are simply exchanged for molded members having a seat 23 of a larger, or of a smaller diameter, as the case may be.
It should be realized, of course, that various other changes and modifications can be made to the described preferred embodiment of the invention, without departing from the spirit and scope of the described invention. For example, the diameter of the contact element 36 may be increased or decreased without affecting the magnitude of the counterforce directed against the inner surface 32 of the wafer 16. The contact element 36 may also be provided with a plurality of contact bumps (not shown) on an upper contact surface 66 of the element 36. In one embodiment, the disk-like contact surface 66 is conically concave to provide an annular contact with the inner surface 32 of the wafer 16. While such a modification locally increases the contact pressure exerted by the contact element 36 against the wafer 16, it again does not alter the magnitude of the counterforce directed against the wafer 16. The magnitude of such counterforce tends to relate directly to a vacuum of a particular magnitude generated in the respective cavity 14.
FIG. 4 shows a wafer holder designated generally by the numeral 70. The wafer holder 70 represents an alternate embodiment of the invention. Structural elements of the wafer holder 70, which function substantially like corresponding elements of the wafer holder 10 are identified by the same numerals as those of the wafer holder 10.
A body or housing 71 determines the structural boundaries of the holder 70. The housing 71 differs from the housing 12 in that a vacuum cavity 72 is formed directly in the housing 71, instead of in a molded, unitary vacuum seat and cavity member 20 as shown in FIG. 1. However, a plurality of such vacuum cavities 72 are located in the housing 71 in the same arrangement as the cavities 14 are arranged in the housing 12 of FIG. 1. Consequently, the sectional view of FIG. 4 represents, as to the arrangement of the cavities in the holder, an equivalent to the section through the vacuum holder 10 shown in FIG. 2.
Each of the vacuum cavities 72 in the holder 70 is bounded by a cylindrical wall 74 of a bore into the housing 71. A rear portion of such cavity 72 is sealed by a resiliently flexible diaphragm 76. The diaphram 76 is preferred to be a molded, substantially planar disk. A peripherally molded ridge 77 on one surface of the diaphragm matches a circular recess 78 in the housing 71. A retainer ring 79 is mounted, preferably by a plurality of plastic mounting screws 81 to a back surface 82 of the housing 71 to retain the diaphragm in sealing contact with the housing.
A seat 23 for holding an article such as the wafer 16 is formed on a front surface 83 in concentricity with the wall 74 of each of the cavities 72. A plurality of the pins 22 are typically spaced about each of the seats 23 to retain the wafer 16 in position when such wafer is first loaded onto the respective seat and before a vacuum becomes established in the cavity 72.
An annular groove 86 in the housing 71 is concentric with each respective cavity 72 and is located within the bounds established by the pins 22 of the respective seat 23. O-rings 21 which are retained in the grooves 86 resiliently support the wafers 16 when they are placed onto the seats 23. The O-rings 21 further provide a vacuum tight seal between the wafers 16 and the housing 71 when a vacuum is drawn in each of the cavities after the wafers 16 have been loaded onto the seats 23. The vacuum becomes established in the cavities 72 in the same manner as already described with respect to the wafer holder 10. A manifold chamber 26 in the upper portion 27 of the housing 71 joins a plurality of vacuum suction ducts 24, each one of which leads through the housing to a respective one of the cavities 72. The manifold chamber is sealed off by the cover plate 28.
The electrical connector 39 for a plurality of electrical leads 38 leading to the cavities 72 is preferably mounted with a vacuum tight seal in the coverplate 28. From the connector, the leads 38 are routed through the manifold chamber 26 and through each of the vacuum suction ducts to the respective vacuum cavities 72.
An inner surface 88 of each diaphragm 76 features a plurality of uniformly spaced blind mounting grommets 89 as integrally molded details of the diaphragm 76. The grommets serve as mounting bases for a plurality of support pins 91 which are inserted into the grommets 89 and extend perpendicularly from the diaphragm 76 toward the seat 23. Because of the resiliency of the diaphragm 76 the pins 91 are preferably guided. A pin guide 92 is an apertured plate adjacent to and offset toward the cavity 72 from a plane 93 wherein a wafer 16 becomes located on the seat 23.
Apertures 94 in the guide 92 coincide with projections of the mounting grommets 89 normal to the plane of the diaphragm 76 toward the seat 23. The guide 92 is preferred to be an integral part of the housing 71. However, the guide 92 may also be provided as a separately maunfactured element. The guides 92, when they are such separate elements, are then subsequently inserted into or mounted to the seats 23 in the housing 71.
The support pins 91 have a predetermined length which locates upper ends 96 of the pins 91 within the respective cavity 72 and adjacent to, but spaced from, the locating plane 93 of the wafers 16. Thus, when the diaphragm 76 is in its rest position, namely in the absence of a vacuum in the cavity 72 of the holder 70, a wafer 16 may be placed onto the respective seat 23 without the wafer contacting any of the pins 91. However, as soon as a vacuum becomes established in the cavities to retain the wafers 16 which have been loaded onto the seats 23, the diaphragm 76 moves inward, toward the cavity 72 and urges the pins 91 against the inner surface 32 of the wafer 16.
The described features of the invention in relationship to the holder 70 serve as an excellent example to highlight certain advantages over those of prior art article holders. Prior art wafer holders do make use, for example, of a plurality of uniformly spaced support pins mounted in a vacuum cavity to support wafers with a distrubuted support and yet with minimal contact area. Such minimal contact area tends to minimize the probability of dirt particles from becoming lodged on such contact surface areas to disturb the planarity of the contact area. to establish the planarity of the contact surface area in prior art wafer holders, the tops of the pins of such prior art holders are lapped with respect to each other to a high degree of planarity.
As can be realized from the above description in reference to the FIG. 4, such high degree of planarity between upper ends 96 of the pins is no longer necessary since the pins 91 are capable of movement toward and away from the inner surfaces 32 of the wafers 16. As a vacuum becomes established in the cavities 72, the upper ends 96 of the pins 91 are urged into contact with the inner surfaces 32 of the respective wafers 16 on the holder 70. The total supporting force directed against the inner surface 32 of each wafer 16 is the result of the differential pressure across the diaphragm 76, resulting from a difference between the ambient pressure and a low partial pressure of the so-called vacuum in the respective cavity 72.
The total force exerted by the pins 91 against the inner surface 32 is consequently related to the net pressure against the diaphragm 76 and to the effective area of the diaphragm 76 as indicated by the dimension "DL" in FIG. 4. The total force exerted by the pins 91 is, however, counteracted and totally offset by an identical pressure-related force directed against a portion of the outer surface 47 of the wafer 16. This latter portion is indicated by the diametral dimension "DU" in FIG. 4. If the total force acting against the outer surface 47 is related to the pressure differential and the surface area of the wafer 16 within the O-ring as shown by the dimension "T", then a substantial portion of the vacuum related holding forces on the wafer 16 are supportively balanced by the pins 91, so that bending stresses on the wafer 16 are minimized.
A particular advantage of the described embodiment resides in that a dirt particle may now become lodged on the upper end 96 of one of the pins 91 without disturbing the planarity of the wafer 16 when the vacuum is applied to the cavity 72. The force of the pin 91 which is exerted against the inner surface through the dirt particle is substantially identical to the force transmitted to the wafer 16 through the pin directly without the dirt particle. The balance of forces has not been changed through the presence of the dirt particles as it would have in the case of rigidly mounted and planarized pins.
Another advantage of the described features becomes apparent when it is realized that the inner surfaces 32 of the wafers 16 are the backsides of ultimate circuits, and it is advantageous to pay less attention to their cleanliness and hence to their planarity. Thus, in prior art holders the surfaces of which had been lapped to a high degree of planarity, stresses and strains may have been introduced in wafers 16 because of defects in planarity on the inner surfaces 32 of the wafers 16. The described wafer holders 10 and 70 afford a balanced supporting force against the inner surface 32 of the mounted wafer 16 regardless of any topographical imperfections on such inner surface.
To avoid a loss in electrical contact of the inner surface 32 to the electrolytic treating circuit 42 (see FIG. 3), the electrical lead 38 is preferably split into several leads 38 within each of the cavities 72, as shown in FIG. 4, so that redundant connections 98 can be made to more than one of the pins 91. Various other changes and modifications may, of course, be made without departing from the spirit and scope of the invention.
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A vacuum-type holder (10) for retaining fragile articles such as semiconductor wafers (16) during a manufacturing operation, such as an electrolytic treatment includes a vacuum-operated support (36) at each of the seats (23) which exerts a supporting force against the underside (32) of the wafer (16) which is opposite to and proportional to a vacuum generated holding force which urges the wafer against the seat. The supporting force, consequently, minimizes bending stresses to which the wafer (16) could otherwise be subjected.
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BACKGROUND OF THE INVENTION
The present invention relates to a process for producing an object from a shapeable material source, for example a viscous or plastic source and having a chiralic structure, as well as to a device for performing this process.
Throughout the remainder of the description the object formed by drawing or any other process will be called a "fibre", but this term does not constitute a limitation to optical fibres.
The monomodal fibres conventionally produced for telecommunications always have a small quantity of linear birefringence and circular birefringence. As a result these fibres retain neither the linear polarization, nor the circular polarization. The fibre can be given a high level of linear birefringence by breaking the circular symmetry to the benefit of a planar symmetry. It is also possible to consider a reverse method consisting of introducing a high circular birefringence, so as to retain the circular polarization.
One solution for producing this circular polarization consists of subjecting the glass fibre to a static torsional stress, e.g. applied externally by twisting between its two ends. One effect of the twisting of the fibre is to introduce circular birefringence into it.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a process making it possible to retain a state of torsion by means of an envelope acting as a hoop or ferrule. It makes it possible to obtain a fibre with a helical or chiralic structure. However, this fibre can have a random cross-section, so that it can have a complex geometry.
If consideration is given to a fibre having a helical symmetry, whereof one production process forms the subject matter of copending U.S. patent application Ser. No. 424,293 filed Sept. 27, 1982 and entitled: "Process for obtaining an object with a chiralic structure resulting from drawing from a softened material source and device for performing this process", it is possible to obtain a fibre, whose properties and structures will be better controlled and which does not have a certain number of the deficiencies inherent in the prior art. This process consists of twisting the object during its drawing and simultaneously hardening it, which makes it possible to fix part of the thus obtained stresses.
A fibre obtained by drawing and stranding after its solidification can have a static fatigue, i.e. it can age and possible microcracks can therefore propagate in its internal structure and can finally lead to the fracture of the object.
To obviate this disadvantage the invention provides for the coating of the fibre with a thermosetting material, which makes it possible to fix the initial state of the fibre and protect it from the mechanical and chemical effects of the invironment.
The present invention specifically relates to a process for producing an object having a chiralic structure obtained by drawing from a shapeable material source and comprising the stages of drawing the object from said material source forming a drawing volume, twisting the object around the drawing axis, hardening the object by cooling the part thereof between the source and the cooled part thereof, coating the object with an object forming an envelope and solidifying the envelope around the object, so as to fix the state of torsion thereof.
The invention also relates to a production device using such a process.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein show:
FIG. 1 diagrammatically the process according to the invention.
FIG. 2 a particular aspect of a prior art process.
FIG. 3 a particular aspect of the production process according to the invention.
FIG. 4 the production process according to the invention.
FIG. 5 a variant of the production process according to the invention.
FIG. 6 a variant of a particular aspect of the production process according to the invention.
FIG. 7 the structure of the fibre obtained by this process.
FIGS. 8 and 9 means for drawing and twisting the fibre.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
On the basis of a stranded helical fibre and the machine making it possible to produce this fibre, as described in copending U.S. patent application Ser. No. 424,293 filed Sept. 27, 1982 and entitled: "Process for obtaining an object with a chiralic structure resulting from drawing from a softened material source and device for performing this process", the following means is proposed for obtaining a fibre retaining the circular polarization.
On considering an already produced fibre, starting e.g. with a preform or blank, and by simple drawing, on twisting a large number of turns whilst holding it at its two ends, it is merely a question of "immobilizing" it to ensure that it retains its polarization properties by means of a rigid hoop, fitted e.g. in accordance with FIG. 1. FIG. 1 illustrates diagrammatically the process according to the invention. It shows an already produced fibre, which has then been tested, whilst being held at its ends 2 and 3. A rigid hoop 4 is then connected in order to immobilize it.
According to the process of the invention, to bring about this retaining action by means of a hoop or ferrule, it is proposed to coat the stranded fibre, during or after its production, with a material which fixes the stranded state of the fibre during solidification.
Thus, through coating the fibre once it has already been stranded simultaneously makes it possible to protect it, fix the torsion which has been produced therein, prevent the ageing of the material by applying radial stresses to it and prevent possible cracks from developing.
This coating can be of glass, vitro-ceramic, plastic or even metal. The advantage of a glass coating is that there is chemical and mechanical compatibility between the stranded fibre and the envelope or hoop deposited on its surface, which prevents ageing. Moreover, the hardened cooled glass has a very long relaxation time, which makes it possible to prevent any mechanical loosening of the coated fibre and in this way the rotatory power of the fibre is retained.
FIG. 2 shows a cross-section of a conventional monomodal fibre blank obtained by the gaseous chemical deposition method, called M.C.V.D. It consists of a core 5, an optical sheath 6 and a mechanical sheath 7 constituted by the initial tube.
FIG. 3 shows a blank for coating in accordance with the present invention. The mechanical sheath 7 has been partly or totally removed.
For example a fibre can be produced from a blank obtained by the M.C.V.D. method, the initial silica tube being dissolved with hydrofluoric acid in order to increase the torsion and polarization effect.
On fibring and stranding this blank without a mechanical sheath, according to the process of the invention, the glass covering process leads to the re-forming of a mechanical sheath, which will also indefinitely retain the twisting of the guiding part and its polarizing optical qualities. To achieve this the fibre is introduced into a melted glass coating device.
The composition of the enveloping glass is chosen so as to ensure a good adhesion to the optical sheath or what is left of the silica mechanical sheath, together with a radial compressive stressing of the fibre during the cooling of the envelope glass, which will ensure that the fibre is insensitive to the external environmental and conditioning stresses and strains. To this end a glass or a vitro-ceramic with a high expansion coefficient is used.
Various methods exist for producing optical fibres. The so-called double crucible method starts with molten material, which is stretched into the form of a fibre. The other production processes give an intermediate stage, e.g. the process starting from a blank produces the fibre to within a homothetic transformation. In a non-limitative manner, consideration will be given to a process of this type for the purpose of explaining the process according to the invention.
FIG. 4 illustrates the different elements of a fibre formation machine using the process according to the invention. These various elements are as follows. A preform or blank 8 positioned within the melting means 9, which can be a blowpipe, a Joule effect furnace, a high, medium or low frequency induction furnace or the like is the source of fibre 1. These melting means 9 soften the blank 8. The material starts to flow and a fibre 1 is obtained by drawing and twisting. Generally the type of blank used is like that shown in FIG. 3.
A coating device 11 containing, for example, molten glass 10 melted by means 12 makes it possible to coat fibre 1, which is stranded during its production. Hardening means 13 are able to store the state of the fibre 1, whilst solidifying the coating material.
The stranded and coated fibre is obtained at 14. 15 and 16 are the means for coating the fibre in order to protect it. The coating can be e.g. an epoxy resin or metal coating. 17 is a fibre formation device making it possible to draw and strand the fibre during production.
Device 17, which corresponds to the aforementioned patent application, is shown in FIGS. 8 and 9. FIG. 8 is a side view of this device, the fibre being drawn vertically from top to bottom and coiled horizontally, within the non-limitative scope of this embodiment. FIG. 9 is a projection view along the drawing and rotation axis, viewed from the fibre formation side.
In accordance with FIGS. 8 and 9, fibre 31 from the not shown shaping means is gripped in rollers 42, 43 of holding device 36 between which it passes and is then deflected towards pulleys 38, 39. Pulley 39 can be moved in translational manner to ensure the transfer of the fibre to the vertically axed winding drum 40. The group of rollers of device 36 and guide pulleys 38 and 39 is integral with a plate 41, whose rotation axis XX' is vertical and coincides with the drawing axis XX' of fibre 31 on leaving the shaping means. The rotation axis of the drum also coincides with axis XX'. This case will be considered throughout the remainder of the description, although it could differ in other constructional embodiments. The rotation of the assembly formed by gantry 37 supporting the pulleys and rollers, as well as plate 41 ensures the twisting of the fibre, whilst the rotation of drum 40 ensures drawing and winding.
Rollers 42 and 43 can be replaced by any other gripping device permitting the drawing of the fibre. They can be coated with a layer of antislip material, such as an elastomer rubber, silicone, neoprene, etc., in order to ensure a good adhesion to the fibre.
The guide pulleys 38, 39, fixed to the rotary gantry makes it possible to wind the fibre on to the central drum 40. If drum 40 and the plate 41-gantry 37 assembly rotate at the same speed, fibre 31 is not wound on to drum 40. However, if drum 40 is kept stationary, one winding turn of fibre 31 on to drum 40 corresponds to one twisting turn of the said fibre. However, the desired result is to obtain a large number of fibre turns per meter.
In addition, if plate 41 rotates at a speed V 1 , it twists the fibre at the same angular velocity. In order to be able to adjust the number of turns per meter of fibre produced, the speed V 2 of drum 40 is chosen, which makes it possible to determine in this way the winding speed v=V 1 -V 2 (or fibre formation speed if expressed linearly).
As a result of the means according to the invention, it is possible to produce fibres having fixed between 1 and 1000 twisting turns per meter. The fibre formation rates can be set at between 1 and 100 m/min. It is possible to fix a considerable proportion of the stresses, due to the shear by twisting, which creates an optical rotatory power in the fibre.
Thus, to start the process, fibre 1 is drawn and stranded by means of device 17 described hereinbefore. The fibre is then passed through the coating cone 11 containing e.g. molten glass 10. Consideration is given to a glass having a high expansion hardening, a significant retraction on the stranded fibre. The external stresses are generally negligible compared with the diametral stresses applied by the hoop or envelope and the coated fibre is insensitive to the medium.
If the envelope product 10 is glass or vitro-ceramic, it is then possible to produce a second coating, from coating device 15, of a protective material 18, which can be plastic or metal.
In the case of a metal or plastic envelope, it is also possible to produce a single thick coating. The plastic in question has a relatively high modulus of elasticity.
In FIG. 4 a single hardening means is shown at 13, but there can also be such a means at the outlet from furnace 9, when the fibre has been stranded in order to fix the state of the fibre.
The hardening means in question can be e.g. a water curtain, a cold radiating panel or a cold gas flow. This can be atmospheric air in the case e.g. of a glass coating.
16 is a device permitting the solidification of the protective coating of material 18 applied by coating device 15. For example in the case of a plastic envelope, this can be a polarisation, particularly with ultra-violet rays. The end fibre obtained 23 has a structure like that described in FIG. 7.
In FIG. 6, two bars 19, e.g. of silica, are welded on either side of the blank. By homothetic transformation during fibre formation, it is thus possible to obtain a fibre having the same elements. The blank and fibre can have identical or slightly different geometries, as a function of the melting conditions chosen.
The blank of FIG. 6, fibred by drawing in accordance with the prior art, would give a fibre having a plane of symmetry enabling the retention of the linear polarization. Once stranded, a linear polarization is obtained, which is twisted. Experience has shown that it is possible to fibre such composite blanks.
Fibre 1 is coated to fix this stranded state making it possible to retain the polarization with an envelope glass 10 using coating device 11.
The thickness of the glass envelope is controlled by adjusting the viscosity of glass 10 (function of the temperature), and the dynamics of fibre formation.
The helica glass lining of a blank, like that described in FIG. 6, adds to the stress effects due to twisting, those due to different expansion coefficients of the glasses present, thereby breaking the axial symmetry of fibre 14. The rectilinear glass lining of such a composite blank will give a fibre retaining the linear polarization.
One means for increasing the torsion is to simultaneously turn the blank 8, if this proves to be necessary. It is possible to obtain a very large number of turns (200/meter) on the fibre, because this torsion is immediately fixed without there being any risk of fracture by ageing and the development of microcracks.
FIG. 5 illustrates a variant of the production process according to the invention. On to the vertical drum of assembly 17 has been wound a fibre obtained e.g. from a blank, like that shown in FIG. 3, by drawing. Assembly 17 makes it possible to unwind fibre 20, so as to obtain by gripping in device 30 a stranded fibre 21, which enters coating device 11 filled with a coating product 10, preferably glass for the aforementioned reasons, said glass being melted by heating means 12. Pressing device 30 prevents the fibre from turning on itself and can be constituted by pulleys, rollers, etc. On leaving coating device 11, the envelope glass applied to the fibre is hardened by hardening means 13 in order to give a hooped fibre 22.
This fibre can be protected by coating means, such as coating device 15, its coating product 18 and treatment means 16. A fibre with a chiralic structure 23 is obtained, which is wound on to a drum by conventional drum winding and transfer means 19.
The fibre obtained from a blank like that of FIG. 3 is shown in FIG. 7. The actual stranded fibre is constituted by a core 24 and a sheath 25 having the properties of a chiralic structure. It is hooped by a glass envelope 26, itself protected by a protective sheath 27.
The fibres obtained in this way by the process of the invention can be used in the production of optical sensors, e.g. electric current sensors.
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The invention relates to a production process consisting in a first variant of drawing, stranding and hardening the object in a simultaneous manner before coating it with a product for forming an envelope making it possible to fix the twisting or torsion of said object. According to a second variant the drawing and hardening stages are performed before the twisting and coating stages.
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PRIORITY
[0001] This application claims priority to Chinese Patent Application No. CN201510564637.8, filed Sep. 8, 2015, and all the benefits accruing therefrom under 35 U.S.C. §119, the contents of which in its entirety are herein incorporated by reference.
TECHNICAL FIELD
[0002] The present invention belongs to the field of elevator safety technologies and relates to a safety device for elevators for decelerating or braking elevators.
BACKGROUND ART
[0003] A safety device for elevators may also be referred to as a “safety arrester”, which is an indispensable component of an elevator to guarantee safe operation of the elevator. With increasing requirements on safety and reliability of the elevator, requirements on deceleration or braking performance of the safety device for elevators are also increased.
[0004] The safety device for elevators is generally provided with a wedge, and in a normal operation of a common elevator, the wedge and a guide rail of the elevator are not in contact (there is a gap distance between the two), and in a deceleration or braking process, the arrestment similar to braking is caused by a frictional force between the wedge and the guide rail of the elevator, where the magnitude of the frictional force reflects the magnitude of an arresting force exerted on the guide rail. For example, when the elevator is in an abnormal state such as fast dropping, a speed limiter disposed in the elevator is used to judge whether a current dropping speed exceeds a predetermined speed value; if the current dropping speed exceeds the predetermined speed value, the speed limiter triggers an action, and further triggers a pulling transmission component of the elevator to act on the wedge of the safety device for elevators, so that a frictional force is generated between the wedge and the guide rail. The frictional force further pulls the wedge to move upward; therefore, the frictional force is increased rapidly, the wedge clamps the guide rail in a self-locking manner, and an elevator car stops moving, thus guaranteeing operation safety of the elevator.
[0005] When classification is carried out according to wedge structures, safety devices for elevators can be classified as symmetric arresters and asymmetric arresters. The U.S. Pat. No. 481,965, which is entitled “Arrester Device for Elevators” and belongs to the prior art, discloses an asymmetric arrester device, including an active wedge and a counter wedge that are asymmetrically disposed on both sides of a guide rail. In a deceleration or braking process, a downward acting force is exerted on the counter wedge through an elastic force of multiple disc springs disposed above the counter wedge, thereby obtaining a desired stable frictional force (that is, an arresting force) that can arrest an elevator car. However, such an asymmetric arrester device has at least the following disadvantages: (1) the force value repeatability of the elastic force generated by the multiple disc springs is poor, and therefore, the working stability of the safety device is easily affected; (2) a force value of the elastic force that can be exerted by the multiple disc springs depends on the number of disc springs superposed, and due to restrictions such as space, the force value of the elastic force that can be generated by the disc springs is usually limited, and a braking effect on a high-speed elevator may be undesirable; (3) due to an excessively high stiffness and an excessively small deformation amount, the disc springs are extremely sensitive to wear of the wedge; as the wear of the wedge changes, the elastic force that is generated by the disc springs when the active wedge moves upward to a predetermined position decreases significantly, the desired frictional force (that is, the arresting force) is hard to achieve, and therefore, there exists a potential safety hazard.
SUMMARY OF THE INVENTION
[0006] To solve one or more aspects of the foregoing problems, the present invention provides a safety device for elevators, including: a housing; a safety piece having a guide rail groove, the safety piece being disposed in the housing; asymmetric active and counter wedges that are slidably disposed on the safety piece at both sides of the guide rail groove, respectively; and
[0007] the safety device for elevators further including a U-shaped elastic element and a blocking piece that are disposed on the safety piece;
[0008] wherein a guide groove is disposed in the safety piece, the blocking piece is capable of moving approximately upward along the guide groove during at least part of a braking process, and the guide groove and the blocking piece are configured to be capable of stopping, during at least a restoration process, a pre-tightening force generated by the U-shaped elastic element from being transferred to the counter wedge; and
[0009] a lower U-shaped end of the U-shaped elastic element fixedly acts on a lower end surface of the safety piece, and an upper U-shaped end of the U-shaped elastic element elastically acts on an upper end surface of the blocking piece, and transfers, through the blocking piece during the at least part of the braking process, at least part of an elastic force of the U-shaped elastic element to the counter wedge that interacts with a lower end surface of the blocking piece.
[0010] Through the following detailed description with reference to the accompanying drawings, the foregoing features and operations of the present invention will become evident, and advantages of the present invention will also become more complete and clearer.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a 3D schematic structural front view of a safety device for elevators according to an embodiment of the present invention;
[0012] FIG. 2 is a 3D schematic structural rear view of a safety device for elevators according to an embodiment of the present invention;
[0013] FIG. 3 is a 3D schematic structural front view of a safety piece in the safety device for elevators of the embodiment shown in FIG. 1 ;
[0014] FIG. 4 is a 3D schematic structural top view of a safety piece in the safety device for elevators of the embodiment shown in FIG. 1 ;
[0015] FIG. 5 is a plot of acceleration vs. time of a safety device for elevators; and
[0016] FIG. 6 is a plot of acceleration vs. friction coefficient of a safety device for elevators.
DETAILED DESCRIPTION
[0017] The present invention will be described more completely with reference to the accompanying drawings. Exemplary embodiments of the present invention are shown in the accompanying drawings. However, the present invention may be implemented according to many different forms, and should not be construed as being limited to the embodiments illustrated herein. On the contrary, these embodiments are provided to make the disclosure of the present invention thorough and complete, and convey the conception of the present invention to those skilled in the art completely. In the accompanying drawings, same reference numerals refer to same elements or components, and therefore, the description thereof is omitted.
[0018] Herein, the orientation terms: “upper”, “lower”, “front”, “rear”, “left” and “right” are defined in the directions shown in FIG. 1 , where FIG. 1 shows a 3D structural diagram, viewed approximately from the front, of a safety device for elevators in normal use according to the present application; it should be understood that, these directional terms are relative concepts, and they are used for relative description and clarity, and may change accordingly as the placement orientation of the safety device for elevators changes.
[0019] FIG. 1 shows a 3D schematic structural front view of a safety device for elevators according to an embodiment of the present invention; FIG. 2 shows a 3D schematic structural rear view of a safety device for elevators according to an embodiment of the present invention; FIG. 3 shows a 3D schematic structural front view of a safety piece in the safety device for elevators of the embodiment shown in FIG. 1 ; and FIG. 4 shows a 3D schematic structural top view of a safety piece in the safety device for elevators of the embodiment shown in FIG. 1 . In FIG. 1 to FIG. 4 , a movement direction of the elevator, that is, a direction of the guide rail, is defined as a z-axis direction, and a vertically upward direction is defined as a positive direction of the z-axis; a direction horizontally perpendicular to the guide rail is defined as an x-axis direction, and a horizontally rightward direction is defined as a positive direction of the x-axis; a direction horizontally perpendicular to the wedge is defined as a y-axis direction, and a direction perpendicularly pointing to the safety piece from the wedge is defined as a positive direction of the y-axis.
[0020] Referring to FIG. 1 and FIG. 2 , a safety device 10 for elevators mainly includes a housing 110 , a safety piece 120 , an active wedge 130 , a counter wedge 140 , a U-shaped elastic element 150 , and a blocking piece 160 . The housing 110 is approximately set as a cuboid structure, and may be made of a high-strength material; the safety piece 120 , the active wedge 130 , the counter wedge 140 , the U-shaped elastic element 150 , the blocking piece 160 , and the like are disposed in an inner space of the housing 110 .
[0021] The safety piece 120 is disposed in the housing 110 via a pin column 170 that is approximately disposed along the x-direction, and the movement of the safety piece 120 along the z-direction is limited by means of the pin column 170 . A spring 171 disposed on the pin column 170 is located between the housing 110 and the left side of the safety piece 120 , and can exert a pressure on a side surface of the left side of the safety piece 120 , thereby limiting the movement of the safety piece 120 along the x-direction. For a specific structure of the safety piece 120 , refer to FIG. 3 and FIG. 4 . A middle portion of the safety piece 120 is provided with a guide rail groove 121 along the z-direction, which is used to receive a guide rail of an elevator, and the guide rail groove 120 is correspondingly aligned with a notch of the housing 110 , so that in normal operation, the guide rail can move up and down freely with respect to the safety device 10 for elevators.
[0022] Referring to FIG. 1 and FIG. 2 continuously, both sides of the guide rail groove 121 of the safety piece 120 are provided with the active wedge 130 and the counter wedge 140 respectively. In this embodiment, the active wedge 130 is disposed on the left side of the guide rail groove 121 , and the counter wedge 140 is disposed on the right side of the guide rail groove 121 . However, it should be understood that, by symmetrically transforming the structure of the safety piece 120 with respect to the guide rail groove 121 , the active wedge 130 and the counter wedge 140 may also be disposed on the right side and the left side of the guide rail groove 121 respectively. In this embodiment, the active wedge 130 and the counter wedge 140 are respectively disposed on slide rail grooves 124 and 123 that are on the left and right sides of the safety piece 120 , and the active wedge 130 and the counter wedge 140 may be provided rollers or similar elements respectively, so that under the effect of an external force, they can slide up and down along the slide rail grooves 124 and 123 respectively. Therefore, the active wedge 130 and the counter wedge 140 are movable wedges, and the arrangement of specific sliding structures thereof with respect to the safety piece 120 is not limited.
[0023] It will be understood that, as the slide rail grooves 124 and 123 are integrally formed with the safety piece 120 , it is sure that the slide rail grooves 124 and 123 are completely fixed with respect to the safety piece 120 , and they can also be regarded as “fixed wedges” as opposed to the movable wedge. Moreover, in this embodiment, a left cover plate 125 and a right cover plate 126 (as shown in FIG. 1 ) are further provided corresponding to the active wedge 130 and the counter wedge 140 respectively. The left cover plate 125 and the right cover plate 126 are specifically fixed on the safety piece 120 via bolts. The left cover plate 125 and the right cover plate 126 may also be regarded as a part of the “fixed wedges” respectively.
[0024] In this embodiment, the active wedge 130 is a right-trapezoid block, and an xy cross section thereof is approximately a right trapezoid. As shown in FIG. 1 , the active wedge 130 has an upper end surface 132 , and a friction surface 131 toward the guide rail (not shown in the figure) in the guide rail groove 121 , where a self-locking angle α, that is, a base angle of the trapezoid, is formed between a lower bottom surface and a trapezoid inclined surface on the left side. The self-locking angle α also reflects angle setting of an inclined surface where the slide rail groove 124 is located, that is, the slide rail groove 124 has an angle of inclination substantially the same as that of the trapezoid inclined surface (the inclined surface on the left side) of the active wedge 130 . In a braking process, the active wedge 130 moves upward along the slide rail groove 124 , and therefore the friction surface 131 moves leftwards to get closer to the guide rail in the guide rail groove 121 ; meanwhile, the active wedge 130 presses the slide rail groove 124 of the safety piece 120 leftwards, and the slide rail groove 124 exerts a rightward counter force on the active wedge 130 , that is, a positive pressure F exerted by the active wedge 130 on the guide rail is increased, thus increasing a frictional force. Therefore, in the braking process, the active wedge 130 has an effect of actively implementing braking, thus being referred to as an “active” wedge.
[0025] In case of normal operation of the elevator (when the safety device 10 for elevators does not work), the active wedge 130 is located at a lowermost end and is in direct contact with the housing 110 (as shown in FIG. 1 ), and upon detecting that the speed of an elevator car exceeds a predetermined value, a speed limiter of the elevator triggers a pulling transmission component of the elevator to pull the active wedge 130 to start to move upward. A travel distance of the active wedge 130 in the slide rail groove 124 is configurable, that is, a travel distance of the upward movement of the active wedge 130 is configurable, and may be configured by using the height of the active wedge 130 and/or the height of an inner top surface 128 of the safety piece 120 (as shown in FIG. 3 ); when the active wedge 130 moves to an uppermost end, the upper end surface 132 of the active wedge 130 contacts the inner top surface 128 of the safety piece 120 , thus being blocked. In this case, an x-direction component of the force exerted by the safety piece 120 on the active wedge 130 , that is, the positive pressure F exerted by the active wedge 130 on the guide rail, substantially reaches a maximum value.
[0026] Referring to FIG. 1 continuously, the counter wedge 140 is an upside-down right-trapezoid block, and an xy cross section thereof is approximately an upside-down right trapezoid. As shown in FIG. 1 , the counter wedge 140 also as a relatively wide upper end surface, a friction surface 141 toward the guide rail (not shown in the figure) of the guide rail groove 121 , and a lower bottom surface and a trapezoid inclined surface that are relatively narrow, where a self-locking angle β is formed between the upper end surface and the trapezoid inclined surface on the right side. The self-locking angle β also reflects angle setting of an inclined surface where the slide rail groove 123 is located, that is, the slide rail groove 123 has an angle of inclination substantially the same that of as the trapezoid inclined surface (the inclined surface on the right side) of the counter wedge 140 . Because the upper end surface of the counter wedge 140 is wider than the lower bottom surface, when the counter wedge 140 is driven to move upward under the effect of the frictional force with the guide rail, the friction surface 141 will move rightward to be away from the guide rail in the guide rail groove 121 , which therefore helps increase a distance between the friction surface 131 and the friction surface 141 , thereby facilitating reduction of the positive pressure F exerted by the friction surface on the guide rail. Therefore, in the braking process, when the active wedge 130 and the counter wedge 140 move upward simultaneously, the counter wedge 140 generates a counter effect with respect to the active wedge 130 , and therefore is referred to as a “counter” wedge.
[0027] By setting the self-locking angle α of the active wedge 130 and the self-locking angle β of the counter wedge 140 , the distance between the two opposite friction surfaces 131 and 141 can be reduced when the active wedge 130 and the counter wedge 140 are moving upward simultaneously. Exemplarily, the self-locking angle α is set within a range of 5°-11°, the self-locking angle β is set within a range of 4°-10°, and the self-locking angle β is 0.5°-1.5° smaller than the self-locking angle α. In this way, even when the counter wedge 140 moves upward simultaneously with the active wedge 130 , the positive pressure F exerted by the two wedges on the guide rail still increases, realizing a self-locking effect.
[0028] Referring to FIG. 1 and FIG. 2 continuously, a U-shaped surface of the U-shaped elastic element 150 is approximately vertically disposed, and a U-shape opening thereof faces towards a negative direction of the y-direction, so that at least the counter wedge 140 and the blocking piece 160 can be disposed within the U-shape opening of the U-shaped elastic element 150 . In this embodiment, above the counter wedge 140 , the safety piece 120 is correspondingly provided with a guide groove 122 (referring to FIG. 3 and FIG. 4 ) that is at least used to receive the blocking piece 160 . Specifically, left and right inner sides of the guide groove 122 are each provided with a guide rail groove 1221 , and left and right external sides of the blocking piece 160 are each correspondingly provided with a pin 163 that protrudes outward. In this way, machining is relatively easy to implement and the pin 163 is limited in the guide rail groove 1221 to slide along the guide rail groove 1221 . For example, when the counter wedge 140 acts upwardly on the lower end surface 162 of the blocking piece 160 , the blocking piece 160 can move upward, in the guide groove 122 , approximately simultaneously with the counter wedge 140 . An angle of inclination of the guide groove 122 may be set to be the same as the angle of inclination of the slide rail groove 123 , that is, having a same size as β; in this way, the U-shaped surface of the U-shaped elastic element 150 also has the same angle of inclination, that is, an angle of inclination with respect to the xy plane also has an approximately same size as β.
[0029] A U-shaped bottom portion of the U-shaped elastic element 150 is disposed in the rear of the safety device 10 for elevators (as shown in FIG. 2 ). The U-shaped opening end of the U-shaped elastic element 150 includes a lower U-shaped end 150 a and an upper U-shaped end 150 b , the lower U-shaped end 150 a fixedly acts on a lower end surface 129 of the safety piece 120 , and the upper U-shaped end 150 b acts on an upper end surface 161 of the blocking piece 160 . Therefore, an inward contraction elastic force of the U-shaped elastic element 150 can be transferred to the counter wedge 140 through the blocking piece 160 .
[0030] In the normal operation of the elevator, the counter wedge 140 falls at a lower position, the lower bottom surface of the counter wedge 140 may be seated on a support elastic element (which is not shown in the figure) that is located below the counter wedge 140 and between the counter wedge 140 and the safety piece 120 , and the upper end surface of the counter wedge 140 is in contact with the blocking piece 160 , but the counter wedge 140 substantially exerts no upward acting force on the blocking piece 160 . To relatively fixedly dispose the U-shaped elastic element 150 on the safety piece 120 , pre-tightening forces need to be respectively biased on the lower end surface 129 and the upper end surface 161 of the blocking piece 160 through the lower U-shaped end 150 a and the upper U-shaped end 150 b of the U-shaped elastic element 150 . Therefore, the “pre-tightening force” defines an elastic force generated when the U-shaped elastic element 150 is initially installed on the safety device 10 .
[0031] In this embodiment, a bottom portion of the guide rail groove 1221 is provided with a blocking portion (not shown in FIG. 3 and FIG. 4 ). When the counter wedge 140 exerts no acting force upwardly, the blocking portion blocks the pin 163 , to implement blocking the downward movement of the blocking piece 160 , so that almost all the pre-tightening force generated by the U-shaped elastic element 150 is exerted on the blocking portion (that is, on the safety piece 120 ), which can realize a function of stopping or even preventing the pre-tightening force generated by the U-shaped elastic element 150 from being transferred to the counter wedge 140 . In the following description about the working principle of the safety device 10 for elevators, advantages and effects brought by the function can be understood.
[0032] The U-shaped elastic element 150 may be, for example, a U-shaped spring, and the amount of deformation thereof is mainly embodied by a change of distance between the lower U-shaped end 150 a and the upper U-shaped end 150 b . Parameters such as stiffness and a U-shaped opening width of the U-shaped elastic element 150 may be set according to parameters such as a stable frictional force (predetermined maximum frictional force) desired by the safety device 10 for elevators, and a distance by which the counter wedge 140 is capable of moving upward. Compared with that of a disc spring, an elastic force generated by the U-shaped elastic element 150 under an amount of deformation is stable in magnitude and fully repeatable.
[0033] The width of the blocking piece 160 is substantially equal to the width of the guide groove 122 , and the height and/or stiffness of the blocking piece 160 can be determined according to parameters such as the opening width of the U-shaped elastic element 150 , the stable frictional force desired by the safety device 10 for elevators, and the distance by which the counter wedge 140 is capable of moving upward.
[0034] The safety device 10 for elevators according to the embodiment of the present invention is installed under an elevator car, and provides an arresting force for the elevator car. The basic working principle of the safety device 10 for elevators according to the embodiment of the present invention is further described below.
[0035] Normal Operation of the Elevator
[0036] In the normal operation of the elevator, the safety device 10 for elevators does not need to provide any arresting force for the elevator car. As shown in FIG. 1 , the active wedge 130 falls at a lowest position, that is, falls on the safety piece 120 ; the counter wedge 140 also falls at a lowest position, and it falls on the support elastic element. In this case, a distance between the friction surface 131 and the friction surface 141 is maximum, and neither friction surface 131 nor friction surface 141 contacts the guide rail of the elevator, so that the operation of the elevator is not affected substantially.
[0037] Braking Process
[0038] In the braking process, the safety device 10 for elevators needs to provide an arresting force for the elevator car immediately. The pulling transmission component triggers the active wedge 130 to start to move upward. As the self-locking angle α is set, when the active wedge 130 ascends to a particular position, the friction surface 131 of the active wedge 130 starts to contact the guide rail, and a frictional force generated between the two continues to drive the active wedge 130 to move upward. Further, the distance between the friction surface 131 and the friction surface 141 becomes shorter, the friction surface 141 also starts to contact the guide rail, and driven by the frictional force, the counter wedge 140 also starts to tend to move upward. However, under the effect of the blocking piece 160 , the counter wedge 140 firstly needs to overcome the pre-tightening force exerted by the U-shaped elastic element 150 on the blocking piece 160 , and thus can move upward. In other words, at least part of the frictional force generated by the guide rail with respect to the counter wedge 140 can be transferred to the upper U-shaped end 150 b of the U-shaped elastic element 150 through the blocking piece 160 , and the elastic force generated by the U-shaped elastic element 150 can be transferred to the counter wedge 140 through the blocking piece 160 , only when the frictional force generated by the guide rail with respect to the counter wedge 140 is greater than the pre-tightening force exerted by the U-shaped elastic element 150 on the blocking piece 160 .
[0039] It will be understood that, the frictional force between the guide rail and the friction surface 131 or 141 is substantially equal to the friction coefficient multiplied by the positive pressure F (that is, a pressure vertically exerted on the guide rail). As the active wedge 130 continues to move upward, the active wedge 130 and the counter wedge 140 respectively press the safety piece 120 leftward and rightward more vigorously, parts toward the guide rail (that is, the positive pressure F) of counter forces that are exerted by the safety piece 120 respectively on the active wedge 130 and the counter wedge 140 increase, and the frictional force continues to increase. The blocking piece 160 and the counter wedge 140 start to move upward only when the frictional force between the guide rail and the counter wedge 140 can overcome the pre-tightening force generated by the U-shaped elastic element 150 and the gravity generated by the blocking piece 160 . Meanwhile, the amount of deformation of the U-shaped elastic element 150 increases, and the contraction elastic force of the U-shaped elastic element 150 also increases; moreover, the elastic force can be at least partially transferred to the counter wedge 140 through the blocking piece 160 , thereby increasing the positive pressure F. Meanwhile, it should be noted that, on the other hand, the upward movement of the counter wedge 140 also causes the friction surface 141 to move leftward, which also reduces the positive pressure F. In this process, because the active wedge 130 still moves upward continuously and the distance between the friction surface 131 and the 141 still decreases continuously, although the friction surface 141 moves leftward, the overall positive pressure F still increases.
[0040] After the active wedge 130 moves upward to a top end and is fixed, that is, after the active wedge 130 slides upward to the upper end surface 132 of the active wedge 130 to contact the inner top surface 128 of the safety piece 120 , and be blocked and fixed, the active wedge 130 no longer contributes to increasing the positive pressure F. In this case, a transient dynamic equilibrium point is formed between the counter wedge 140 and the U-shaped elastic element 150 . In other words, the counter wedge 140 is enabled to move to a position point (where the position point is not fixed, and may vary as the friction coefficient or the like changes), so that the magnitude of the frictional force between the counter wedge 140 and the guide rail substantially corresponds to an elastic force, which has a particular value, of the U-shaped elastic element 150 and substantially remains stable, the frictional force does not change significantly with the relative movement or the frictional coefficient between the guide rail and the friction surface 141 , and the magnitude of the friction is the desired stable frictional force or arresting force. For example, if the frictional force cannot reach the desired magnitude because the positive pressure F is not large enough, the counter wedge 140 continues to move upward; therefore the elastic force of the U-shaped elastic element 150 increases, and a positive feedback helps increase the positive pressure F, till the frictional force reaches the desired magnitude. Further, for another example, if the frictional force cannot reach the desired magnitude because the friction coefficient changes (the friction coefficient between the friction surface 141 and the guide rail is variable, and may change with different working conditions), the counter wedge 140 continues to move upward; therefore the elastic force of the U-shaped elastic element 150 increases, and a positive feedback helps increase the positive pressure F, till the frictional force reaches the desired magnitude. Therefore, in this structure, the positive pressure F is fully self-adjustable with respect to the change of the friction coefficient.
[0041] After the dynamic equilibrium is reached, the magnitude of the frictional force is substantially stable, so that a substantially stable acceleration condition can be generated for the elevator car, achieving a desirable braking effect.
[0042] FIG. 5 shows a plot of acceleration vs. time of the safety device for elevators according to an embodiment of the present invention. As shown in FIG. 5, 51 is a plot of acceleration vs. time of an existing safety device for elevators, 52 is a plot of acceleration vs. time of the safety device 10 for elevators, and the braking working process begins at the third second, where the friction coefficient fluctuates. It can be found by comparison that the safety device 10 for elevators in the embodiment of the present invention can obtain a stable acceleration condition in an arresting process (for example, an acceleration value is substantially stabilized at approximately 0.9 g), and a phenomenon of sudden acceleration climbing will not occur even when an arresting time increases.
[0043] It should be understood that, herein, the “stable” frictional force, arresting force or acceleration condition does not refer to a fixed numerical value without any change; instead, the frictional force, arresting force or acceleration condition may remain relatively stable within an interval range, and therefore, they are relative concepts.
[0044] FIG. 6 shows a plot of acceleration vs. friction coefficient of the safety device for elevators according to an embodiment of the present invention. As shown in FIG. 6, 61 is a plot of acceleration vs. friction coefficient of an existing safety device for elevators, and 62 is a plot of acceleration vs. the friction coefficient of the safety device 10 for elevators, where it is reflected that the acceleration of the safety device 10 for elevators is more stable on the condition that the friction coefficient fluctuates.
[0045] It can be learned from the foregoing braking principle analysis that, in case where other parameter conditions are absolutely determined, at the foregoing dynamic equilibrium point, when the counter wedge 140 moves to a particular position point, a corresponding elastic force that the U-shaped elastic element 150 is capable of generating can be absolutely determined through calculation. Therefore, the corresponding elastic force that the U-shaped elastic element 150 is capable of generating at this position point may be set and determined in advance, to roughly determine the magnitude of the frictional force, so that the acceleration condition, which can be generated by the safety device 10 for elevators, is stable as desired. Specifically, the relatively stable frictional force or arresting force desired by the safety device 10 for elevators may be roughly obtained by setting the stiffness and/or opening width of the U-shaped elastic element 150 . Therefore, the U-shaped elastic element 150 is one of crucial components of the safety device 10 for elevators.
[0046] The safety device 10 for elevators of this embodiment fully combines and utilizes performance features of the U-shaped elastic element 150 . The elastic force generated by the U-shaped elastic element 150 under an amount of deformation is stable in magnitude and fully repeatable. Therefore, the acceleration condition that is desired to be generated after the dynamic equilibrium can be relatively stable; moreover, the U-shaped elastic element 150 has a relatively large amount of deformation, and the desired frictional force or acceleration condition can be easily set in an expanded range, which is flexible in design and is fully applicable to high-speed elevators requiring relatively high arresting acceleration. More importantly, even if the counter wedge 140 or the like is worn, the U-shaped elastic element 150 is relatively insensitive to the wear because the structure of the U-shaped elastic element 150 determines that it has smaller stiffness compared with a disc spring. Although the amount of deformation of the U-shaped elastic element 150 increases in the dynamic equilibrium condition due to the wear, and the desired frictional force changes, that is, the desired acceleration condition changes, the amount of deformation is still in a range relatively easy to accept, and the phenomenon that no arresting force can be generated will not occur at all, achieving desirable safety and reliability.
[0047] Moreover, it should be further understood that, especially in case where the blocking piece 160 is disposed to stop the pre-tightening force from being exerted on the counter wedge 160 , in the foregoing braking process, while the counter wedge 140 is overcoming the pre-tightening force exerted by the U-shaped elastic element 150 on the blocking piece 160 , the blocking piece 160 does not move upward, and the amount of deformation of the U-shaped elastic element 150 does not change, and the upper U-shaped end 150 b does not move upward either, which helps reduce the amount of deformation of the U-shaped elastic element 150 in the dynamic equilibrium condition, and further helps expand a setting range of the desired acceleration condition.
[0048] Restoration Process
[0049] In the restoration process, the safety device 10 for elevators needs to restore a normal operation state from a braking state. An elevator control system drives the elevator car and the safety device 10 for elevators to move upward with respect to the guide rail, and the guide rail generates a downward frictional force against the active wedge 130 and the counter wedge 140 in contact with the guide rail on both sides, to drive the active wedge 130 and the counter wedge 140 to move downward. The active wedge 130 slides downward as being driven by the frictional force, causing the positive pressure F to decrease, and the counter wedge 140 also slides downward as being driven by the frictional force, causing the positive pressure F to increase. The decreasing speed of the positive pressure F is greater than the increasing speed thereof, and after the blocking piece 160 is restored to the original position as shown in FIG. 1 , the pin 163 is blocked, stopping the pre-tightening force generated by the U-shaped elastic element 150 from being transferred to the counter wedge 140 , which helps reduce the descending movement of the counter wedge 140 , and thereby helps make the restoration process smoother.
[0050] Besides, it should be understood that, the safety device 10 for elevators of the embodiment of the present invention can ultimately generate a frictional force and acceleration of a relatively stable magnitude (as shown in FIG. 5 ) in the braking process, and will not generate an excessively large frictional force due to changes of the friction coefficient or the like; therefore, the active wedge 130 and the counter wedge 140 will not clamp the guide rail excessively tightly either, so that the restoration is easier and faster.
[0051] The examples above mainly illustrate the safety device for elevators of the present invention. Although only some implementation manners of the present invention are described, those of ordinary skill in the art should understand that the present invention can be implemented in many other forms without departing from the subject matter and scope of the present invention. Therefore, the demonstrated examples and implementation manners are regarded as being illustrative rather than limitative, and the present invention may cover various modifications and replacements without departing from the spirit and scope of the present invention as defined in the appended claims.
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The present invention provides a safety device for elevators, which belongs to the field of elevator safety technologies. The safety device for elevators includes a housing; a safety piece having a guide rail groove, the safety piece being disposed in the housing; and asymmetric active and counter wedges that are slidably disposed on the safety piece at both sides of the guide rail groove, respectively. Moreover, the device further includes a U-shaped elastic element and a blocking piece that are disposed on the safety piece. The safety device for elevators can provide a relatively stable arresting force, is reliable in repetitive work, achieves high safety, is relatively easy as well as fast and efficient in restoration, and is especially suitable for high-speed elevators.
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FIELD OF THE INVENTION
The present invention relates to a method and system for changing a subscription information of a subscriber in a data network. In particular, the present invention relates to a change of a subscription in an Internet Protocol (IP) multimedia subsystem (IMS) environment.
BACKGROUND OF THE INVENTION
In order to achieve access independence and to maintain a smooth interoperation with wired terminals across the internet, the IMS as specified e.g. in the 3GPP specification TS 23.228 has been developed to be conformant to IETF (Internet Engineering Task Force) “Internet Standards”. The IP multimedia core network (IM CN) subsystem enables network operators of mobile or cellular networks to offer their subscribers multimedia services based on and built upon Internet applications, services and protocols. The intention is to develop such services by mobile network operators and other 3 rd party suppliers including those in the Internet space using the mechanisms provided by the Internet and the IM CN subsystem. The IMS thus enables conversions of, and access to, voice, video, messaging, data and web-based technologies for wireless users, and combines the growth of the Internet with the growth in mobile communications.
FIG. 1 shows an architecture of an IMS network according to the above 3GPP (3 rd Generation Partnership Project) specification. The architecture is based on the principle that the service control for home subscribed services for a roaming subscriber is in the home network HN, e.g. a Serving Call State Control Function (S-CSCF) is located in the home network HN. In FIG. 1 , a current or old S-CSC-Fo 10 and a future or new S-CSCFn 12 are shown, between which a terminal device or user equipment (UE) 40 is to be transferred due to changed required capabilities resulting from a change in the subscriber profile of the UE 40 .
In general, an S-CSCF performs the session control service for the served UEs. It maintains a session state as needed by the network operator for support of the services. Within an operator's network, different S-CSCFs may have different functionalities. The functions performed by the S-CSCF during a respective session are e.g. registration, session flow management, charging and resource utilization management. When a subscriber roams to a visited network VN, the visited network VN supports a Proxy-CSCF (P-CSCF) 30 which enables the session control to be passed to the respective S-CSCF located at the home network HN and providing the service control. Furthermore, an Interrogating-CSCF (I-CSCF) 50 is provided in the home network HN as a contact point within the operator's network for all connections destined to a subscriber of that network operator, or a roaming subscriber currently located within that network operator's service area. There may be multiple I-CSCFs within an operator's network. The functions performed by the I-CSCF 50 include assigning an S-CSCF to a user performing a registration procedure, routing a request received from another network towards the S-CSCF, maintaining the address of an S-CSCF from a subscriber database, e.g. a Home Subscriber Server (HSS) 20 as shown in FIG. 1 , and/or forwarding requests or responses to the S-CSCF determined based on the address of change from the HSS 20 .
The P-CSCF 30 is the first contact point within the IMS. Its address is discovered by the UE 40 following a PDP (Packet Data Protocol) contact activation. The P-CSCF 30 behaves like a proxy, i.e. it accepts requests and services them internally or forwards them on, possibly after translation. The P-CSCF 30 may also behave as a User Agent, i.e. in abnormal conditions it may terminate and independently generate transactions. The functions performed by the P-CSCF 30 are forwarding register requests received from the UE 40 to an I-CSCF, e.g. the I-CSCF 50 , determined using the home domain name as provided by the UE 40 , and forwarding requests or responses to the UE 40 .
Further details regarding the functions of the different CSCF elements shown in FIG. 1 can be gathered from the above mentioned 3GPP-specification.
According to the conventional network architecture in the above mentioned 3GPP Release 5 specification, the HSS 20 is not aware of the kind of capabilities a specific S-CSCF has in the network. On the contrary, the HSS 20 knows what kind of capabilities an S-CSCF needs to support a specific subscriber. This information is stored in a subscriber profile of the specific subscriber. During an initial registration process of UE 40 , the HSS 20 sends the required S-CSCF capabilities to the I-CSCF 50 and the actual selection of the S-CSCF is done by the I-CSCF 50 . The selection at the I-CSCF 50 is performed on the basis of an information indicating the required capabilities and received from the HSS 20 .
However, when there is a need for updating the subscriber profile e.g. in the S-CSCFo 10 currently serving the UE 40 , the HSS 20 cannot know whether the selected S-CSCFo 10 is still capable of adequately serving the subscriber of the UE 40 . It may be possible that new capabilities required according to the new subscriber profile are not supported by the S-CSCFo 10 . Another possibility is that the service provider has removed some service from the subscriber profile and thus has prevented the usage of this service or service part.
If the capability of the S-CSCFo 10 does not meet with the updated subscriber profile, the subscriber is not able to use all subscribed services, or may received services which he or she is no longer willing to have. Furthermore, the subscriber may be charged for services which he or she has been cancelled. Moreover, if the network operator has denied services, the subscriber may still be able to use these services which he or she is no longer authorized to use.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method and system for changing a subscription, by means of which an adequate or matched serving function can be assured even after a change in the subscriber profile of a subscriber.
This object is achieved by a method for changing a subscription information of a subscriber in a data network, said method comprising the steps of:
detecting a change in said subscription information of said subscriber; checking whether a capability of a network element serving a terminal device of said subscriber is still in accordance with said changed subscription information; and initiating in response to the result of said checking step a registration procedure for registering said terminal device of said subscriber to a new serving network element.
Furthermore, the above object is achieved by a system for changing a subscription information of a subscriber in a data network, said system comprising:
detecting means for detecting a change in said subscription information of said subscriber; checking means for checking whether a capability of a network element serving a terminal device of said subscriber is still in accordance with said changed subscription information; and initiating means for initiating in response to said checking means a registration procedure for registering said terminal device of said subscriber to a new serving network element.
Additionally, the above object is achieved by a subscriber database for storing a subscription information of a subscriber of a data network, said database being arranged to detect a change in said subscription information and to initiate a registration procedure for registering a terminal device of said subscriber to a new serving network element in response to the result of the checking operation for checking whether a capability of a network element serving a terminal device of said subscriber is still in accordance with said changed subscription information.
Accordingly, when a subscriber profile of a subscriber is updated or changed, a capability mismatch at the serving network element is automatically detected and a new serving network element having adequate capabilities is allocated by initiating the registration procedure. Thereby, any new subscription information can be taken into account almost immediately when it has been configured or stored in the subscriber database of the data network.
The checking step may comprise checking whether said serving network element is still capable of serving said terminal device of serving said terminal device of said subscriber in view of said changed subscription information.
The detection step may be based on a detection of a subscriber profile update, or may be based on a detection of a subscription of said subscriber to a new service.
According to an advantageous further development, the checking step may be performed on the basis of a capability information added based on said detection step to a response message of a registration procedure initiated by said terminal device. In this case, the registration procedure may be initiated by said terminal device in response to a de-registration procedure initiated when a change of said subscription information has been detected in said detection step. Alternatively, the registration procedure may be a periodic registration procedure initiated at predetermined intervals.
Preferably, a configuration information may be provided for determining subscribed services needing predetermined serving network elements.
According to another advantageous further development, the checking step may comprise the steps of transmitting a capability query comprising at least one required capability to the serving network element, comparing capabilities of the serving network element with the at least one required capability, and receiving an acknowledgement indicating the result of the comparing step from the serving network element. As an alternative, the checking step may comprise the steps of transmitting an information indicating at least one required capability and an identification of said serving network element to an interrogating network element, checking at said interrogating network element whether said serving network element fulfills said at least one required capabilities, and receiving an acknowledgement indicating the result of said checking step from said interrogating network element. Then, a de-register message for de-registering the terminal device may be sent to the serving network element in response to the received results of the comparing step. A re-registration procedure may then be initiated by the terminal device in response to a message issued by the serving network element. In this case, the de-register message may include a cause information which indicates that the reason for de-registration was a need for changing the subscriber information.
As an alternative to the network-initiated re-registration procedure, a selection function of the data network may be initiated using the at least one required capability, and a resulting identification information of the new serving network element may be notified to a proxy network element connected to the terminal device. The notification may be performed using an identification of the proxy network element stored at a subscriber database. The identification may be requested from the serving network element using the de-register message. The selection function may be performed by an interrogating network element.
As a further alternative, the checking step may be performed by requesting from the data network a capability list containing an information about required capabilities of serving network elements. In particular, the capability list may be requested from an interrogating network element. Thus, the checking means may be the interrogating network element, e.g. an I-CSCF of the IMS. The interrogating network element may be arranged to perform that checking operation based on a capability information received with a registration authorization response.
The detection means may be a subscriber database e.g. a HSS. Thus, the change of the subscriber profile at the subscriber database can be detected directly so as to check the capability and initiate a registration procedure, if required.
The initiating means may be the subscriber database, wherein the registration procedure is initiated by initiating the selection function of the data network core, or alternatively, by issuing the de-register message. As an alternative, the initiating means may be an interrogating network element arranged to issue a register message to the new serving network element.
The subscriber database may be arranged to inhibit an unnecessary registration based on a configuration information provided at said database.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the present invention will be described in greater detail based on preferred embodiments with reference to the accompanying drawings, in which:
FIG. 1 shows a schematic network architecture in which the preferred embodiments of the present invention can be implemented;
FIG. 2 shows a message signaling and processing diagram indicating a subscription change procedure according to a first preferred embodiment;
FIG. 3 shows a message signaling and processing diagram indicating a subscription change procedure according to a second preferred embodiment;
FIG. 4 shows a message signaling and processing diagram indicating a subscription change procedure according to a third preferred embodiment; and
FIG. 5 shows a message signaling and processing diagram indicating a subscription change procedure according to a fourth preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments will now be described on the basis of an IMS network architecture as shown in FIG. 1 .
The IMS shown in FIG. 1 refers to a set of core network entities using the services provided by the packet-switched domain to offer multimedia services. The HSS 20 is the master database for a given user and includes the functions of conventional home location registers (HLRs) as well as new functionalities specified to IP networks, such as the IMS. The HSS 20 is the entity containing the subscription-related information to support the network entities actually handling calls and/or sessions. The home network HN may contain one or several HSSs depending on the number of mobile subscribers, on the capacity of the equipment and on the organization of the network. The HSS 20 may integrate heterogeneous information, and enable enhanced features in the core network to be offered to the application and services domain. In particular, the HSS 20 is responsible for holding user-related information, such as user identification, numbering and address information, user security information, user location information, and user profile information. Based on this information, the HSS 20 is also responsible of supporting the call control and session management entities of the different domains and subsystems, such as the IMS, a Radio Network Subsystem (RNS), etc.
According to the preferred embodiments, a registration procedure for registering the UE 40 to the new S-CSCFn 12 is initiated if a capability check indicates that the current S-CSCFo 10 is no longer capable of serving the UE 40 after a change in the subscription information of the respective subscriber. This automatic or semi-automatic adaptation of the serving network element or entity in response to a capability check can be performed in various ways, as described in the following four preferred embodiments. When the subscription or subscriber profile is changed for a subscriber, e.g. the subscriber subscribes new service(s) it is possible that the already assigned S-CSCFo 10 cannot support the new service(s).
In order to assign a new S-CSCFn 12 capable for serving the subscriber, the following procedure indicated in FIG. 2 can be performed according to the first preferred embodiment.
As shown in FIG. 2 , the HSS 20 de-registers the subscriber by sending a corresponding de-register message via the S-CSCFo 10 to the UE 40 (steps 1 and 2 ), which will lead to a situation where the UE 40 automatically initiates a new initial registration procedure, because the de-register message contains a cause code which indicates the reason for de-registration. This cause code or cause information is added by the HSS 20 in response to the detection of a change in the subscription information or subscriber profile of the concerned subscriber. This will lead to a situation where a new S-CSCF, e.g. the S-CSCFn 12 , will be selected based on the new subscriber profile. In order to avoid unnecessary de-registrations, the HSS 20 may contain some configuration information used to determine what kind of services need special S-CSCFs. The UE 40 sends a registration message for a new registration to the I-CSCF 50 (step 3 ). The I-CSCF then sends a registration authorization message to the HSS 20 (step 4 ). As the HSS 20 knows that the subscription was changed, it sends a registration authorization response with the capability information and name of the current S-CSCFo 10 to the I-CSCF 50 , instead of only the name of the S-CSCF 50 as in the conventional procedure. It is noted that the HSS 20 may as well only send the capability information of the current S-CSCFo 10 (step 5 ). Then, the I-CSCF 50 may use both or only the S-CSCF capability information to decide which actions it has to take, i.e. whether to select a new S-CSCF or not (step 6 ). Based on the checking result, the I-CSCF 50 either sends a registration message to the current S-CSCFo 10 or to a selected new S-CSCFn 12 having the required capability (step 7 ).
Thereby, the serving network function can be adapted to the changes in the subscriber profile of the concerned subscriber. If the old or current S-CSCFo 10 fulfills the S-CSCF capability requirements, the old S-CSCF 10 is selected during the new registration process.
FIG. 3 shows a message signaling and processing diagram indicating a subscription change procedure according to the second preferred embodiment. In the second preferred embodiment, the HSS 20 does not initiate any actions before the UE 40 sends a normal periodic registration message to the network, e.g. to the I-CSCF 50 (step 1 ). When the periodic registration, i.e. a registration authorization message arrives at the HSS 20 (step 2 ), the HSS 20 knows that the subscription was changed and sends a registration authorization response message containing a capability information and name of the current S-CSCFo 10 to the I-CSCF 50 instead of only the name of the current S-CSCFo 10 (step 3 ). Also in the present case, it is noted that the HSS 20 may only send the capability information. The I-CSCF 50 uses both or only the S-CSCF capability information to decide which actions it has to take, i.e. whether to select a new-CSCF, e.g. the new S-CSCFn 12 , or not (step 4 ). In the case shown in FIG. 3 , the new S-CSCFn 12 is selected by transmitting a register message to the S-CSCFn 12 (step 5 ) because the old assigned S-CSCFo 10 does not fulfill the requirements in order to provide the appropriate services for the subscriber of the UE 40 .
In the above described first and second preferred embodiments, the automatic re-registration may be accompanied by a new functionality to clear the name of the old S-CSCFo 10 from the HSS 20 or to provide a corresponding flag information.
According to the following third and fourth preferred embodiments, the HSS 20 first checks whether the current S-CSCFo 10 supports the new requirements needed by the changed subscriber profile or subscription information and initiates a corresponding subscriber profile or serving entity selection or change procedure, based on the result of the checking operation. If the current S-CSCFo 10 can support the new requirements, the new subscriber profile is updated in the current S-CSCFo 10 . If the current S-CSCFo 10 cannot support the new requirements, then the HSS 20 starts a procedure leading to a change to the new S-CSCFn 12 . It is noted that in the third and fourth preferred embodiments it is assumed that the UE 10 is located in the visited network VN and connected via the P-CSCF 30 .
According to the third preferred embodiment, a network-initiated de-register procedure is started, which leads to a situation where the UE 40 automatically initiates a new initial re-registration procedure due to the fact that a de-register message issued by the HSS 20 contains a cause code which unambiguously reveals the reason for the de-registration. This leads to a situation where the new S-CSCFn 12 will be selected based on the new subscriber profile.
FIG. 4 shows a message signaling and processing diagram indicating a subscription change procedure according to the third preferred embodiment. When a new subscriber profile has been issued, the HSS 20 sends a capability query to the currently selected S-CSCFo 10 (step 1 ). The capability query contains the new required capabilities. It is noted that this operation could be added to the existing profile uploading from the HSS 20 to the current S-CSCF 10 or it could be a new mechanism between the HSS 20 and the current S-CSCFo 10 . The current S-CSCFo 10 compares its own capabilities to the required capabilities and makes a decision whether it can support the required capabilities, or not. Then, the current S-CSCFo 10 sends a capability response to the HSS 20 , including a positive or negative acknowledgement (step 2 ). If the current S-CSCFo 10 cannot serve the subscriber anymore due to lack of capabilities, it will send a negative acknowledgement. If the current S-CSCFo 10 can still serve the subscriber, it will send a positive acknowledgement to the HSS 20 . If a new subscriber profile was send, a current S-CSCFo 10 may store it for further use.
If the HSS 20 receives a positive acknowledgement, then it ends the selection or change procedure. If the subscriber profile was not sent in step 1 , then the HSS 20 starts a subscriber profile uploading procedure as specified in the above mentioned 3GPP specification.
If the HSS 20 receives a negative acknowledgement, it initiates a network-initiated de-registration process by sending a de-register message to the current S-CSCFo 10 with a cause code which clearly identifies that the reason was a need for updating the subscriber profile (step 3 ). The current S-CSCFo 10 receives the message from the HSS 20 and generates an appropriate SIP (Session Initiation Protocol) message, e.g. a NOTIFY message, with an appropriate cause code and sends it to the P-CSCF 30 (step 4 ). The P-CSCF 30 then forwards the SIP message to the UE 40 (step 5 ). This allows the UE 40 to automatically and immediately start a re-registration procedure. In particular, the UE 40 receives the SIP message transmitted in steps 4 and 5 and detects the need for registration. Then, the UE 40 starts a registration process as specified in the above mentioned 3GPP specifications (step 6 ). Thereby, an adequate serving network entity can be selected.
According to the fourth preferred embodiment, the HSS 20 starts a new procedure which would change the assigned current S-CSCFo 10 to the new S-CSCFn 12 supporting the new requirements without involving the UE 40 . It may be possible that the network is not able to deliver the network initiated de-register message to the UE 40 , e.g. if the UE 40 has not been subscribed to a registration event report package.
FIG. 5 shows a message signaling and processing diagram indicating a subscription change procedure according to the fourth embodiment. When a new subscriber profile has been issued, the HSS 20 sends a capability query to the current S-CSCFo 10 (step 1 ). The capability query contains new required capabilities according to the new subscriber profile. Also in the present case, the operation could be added to the existing profile uploading from the HSS 20 to the current S-CSCFo 10 or it could be a new mechanism between the HSS 20 and the current S-CSCFo 10 .
Having received the capability query, the current S-CSCFo 10 compares its own capabilities to the required capabilities and makes a decision whether it can support the required capabilities, or not. If the current S-CSCFo 10 cannot anymore serve the subscriber due to lack of capabilities, it will send a capability response with a negative acknowledgement to the HSS 20 (step 2 ). If the current S-CSCFo 10 can still serve the subscriber, it will send a positive acknowledgement to the HSS 20 . If a new subscriber profile was sent to the current S-CSCFo 10 , then it stores it for further use.
If the HSS 20 receives a positive acknowledgement, it ends the procedure.
If the subscriber profile was not sent in step 1 , then the HSS 20 starts a subscriber profile uploading procedure as specified in the above mentioned 3GPP specifications.
If the HSS 20 receives a negative acknowledgement, as indicated in FIG. 5 , the HSS 20 sends a de-register message to the current or old S-CSCFo 10 which currently serves the subscriber of the UE 40 . This message contains a request for the address and/or name of the P-CSCF 30 of the visited network VN (step 3 ). The current S-CSCFo 10 receives the de-register message and acknowledges the message with the address and/or name of the P-CSCF 30 (step 4 ). The current S-CSCFo 10 may then delete the existing subscriber profile of the concerned subscriber. Due to the fact that the de-register message contained a request to send the address and/or name of the P-CSCF 30 , the current S-CSCFo 10 does not send any notification to the P-CSCF 30 . The HSS 20 receives the acknowledgement with the address and/or name of the P-CSCF 30 and temporarily stores the subscribers' P-CSCF address and/or name (step 5 ). It is noted that the address and/or name of the P-CSCF 30 may be stored permanently in the HSS 20 . Then, it is not necessary for the HSS 20 to request the address and/or name of the P-CSCF 30 in step 3 .
In step 6 , the HSS 20 sends a message to the I-CSCF 50 , including the subscriber identity and new capabilities required by the subscriber according to the changed subscription information. This message may be a message to initiate a selection function for selecting a new serving entity. In response to the receipt of the message, the I-CSCF 50 initiates a new S-CSCF selection for the subscriber based on the new required capabilities (step 7 ). Then, the I-CSCF 50 sends a register message to the newly selected S-CSCFn 12 including the subscriber identity (step 8 ). In response thereto, the new S-CSCFn 12 starts a subscriber profile uploading procedure as specified in the above mentioned 3GPP specification (steps 9 to 12 ).
When the subscriber profile has been updated, the new S-CSCFn 12 generates an appropriate SIP message, e.g. a NOTIFY message, including the address of the new S-CSCFn 12 , and sends it to the P-CSCF 30 (step 13 ). In step 14 , the P-CSCF 30 stores or updates the S-CSCF address to be used in future sessions (step 14 ). Finally, the P-CSCF 30 acknowledges to the new S-CSCFn 12 with a SIP 200 OK message, the new S-CSCFn 12 acknowledges to the I-CSCF 50 with a SIP 200 OK message, and the I-CSCF 50 sends a corresponding acknowledgement to the HSS 20 . Then, the serving network entity has been adapted to the changed subscriber profile.
The capability checking operation performed by the HSS 20 in the third and fourth preferred embodiment may be replaced by the following checking procedure. According to this alternative checking procedure, the HSS 20 may send a query for a capability list to the I-CSCF 50 . This message may contain the required capabilities of the new S-CSCF. Then, the I-CSCF 50 checks the required capabilities and reports the list of available S-CSCFs to the HSS 20 . The HSS 20 then checks if the current S-CSCFo 10 is included in this capability list.
As a further alternative checking procedure, the HSS 20 may send the address of the current or old S-CSCFo 10 together with the new required capabilities according to the updated or changed subscriber profile to the I-CSCF 50 in a corresponding updating message, in a first step. Then, in a second step, the I-CSCF 50 acknowledges to the HSS 20 whether the old S-CSCF 10 fulfills the new requirement(s). Based on the acknowledgement received from the I-CSCF 50 , the HSS 20 may then act in the following alternative ways. If the requirement(s) is/are fulfilled by the old S-CSCFo 10 , a profile update from the HSS 20 to the I-CSCF 50 is initiated. If not, the HSS 20 initiates a network initiated de-registration procedure or S-CSCF selection procedure as described in connection with FIGS. 4 and 5 , respectively.
The need for capability negotiation may be decreased by using a default S-CSCF instead of the capability based selection. Thus, when it is detected that the current S-CSCFo 10 is not capable of serving the subscriber in view of the changed subscription information, the default S-CSCF could be selected.
Furthermore, the capability query of the HSS 20 may be integrated to an existing PPR diameter command in the Cx interface between the HSS 20 and the S-CSCF and/or I-CSCF functionality.
If the UE 40 cannot be informed to make a new registration in the third preferred embodiment, the P-CSCF 30 may initiate the new registration after receiving the notifying message. Then, the only element which requires changes would be the P-CSCF 30 .
As a further alternative, the HSS 20 may know all capabilities of the S-CSCFs provided in the network. To achieve this, a corresponding table may be stored at the HSS 20 . Then, the capability queries either from the I-CSCF 50 or the current S-CSCFi 10 would not be required in the third and fourth preferred embodiments. The checking operation may then be performed within the HSS 20 . Moreover, if the HSS 20 contains some configuration information, unnecessary de-registrations can be avoided.
Additionally, in the context of a subscriber profile update it may be notified that the old S-CSCF 10 does not support a new subscriber profile allocated thereto. Then, a change of the S-CSCF may be initiated based on a negotiating procedure similar to the capability queries of the first and second embodiments. I.e., if the old S-CSCF 10 receives the new subscriber profile from the HSS 20 , it sends an acknowledgement message which may contain a reason, e.g. “service failed” or “service not known” etc., to the HSS 20 , indicating that it does not support this kind of profile.
It is noted that the present invention is not restricted to the preferred embodiments described above. The present invention may be implemented in any data network, where a subscription information of a subscriber has impact on the required capabilities of the serving network element. Thus, the designations and functions of the network elements or entities and signaling messages may be different in other or future data networks. The embodiments may thus vary within the scope of the attached claims.
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The present invention relates to a method and system for changing a subscription information of a subscriber in a data network. When a subscriber profile or subscription information is changed or updated, this is detected and a registration procedure for registering a terminal device ( 40 ) of the subscriber to a new serving network element ( 12 ) is initiated in response to the result of a checking step for checking whether a capability of a network element ( 10 ) serving a terminal device ( 40 ) of said subscriber is still in accordance with said changed subscription information. Thereby, an automatic or semi-automatic adaptation of the serving entity to the changed subscription can be achieved.
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This is a continuation of copending application Ser. No. 08/497,393 filed on Jun. 30, 1995, now abandoned.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to fishing lures and more particularly, to glass, plastic and metal clicking capsules for fishing lures, wherein the clicking capsules are inserted in the bodies of soft, flexible plastic fishing lures such as simulated worms, grubs, crawfish and the like and inserted in bored or molded apertures, cavities or openings provided in hard body fishing lures such as jigs, top-water lures and "crank baits". In a first preferred embodiment, the clicking capsule is characterized by a transparent, plastic or glass ampoule or capsule which encapsulates one or more clicking elements constructed of a selected length of metal wire and therefore having a cylindrical cross-section, with rounded or blunt, squared or tapered ends. The clicking elements may be of the same or dissimilar diameter, length and end configuration and are sufficiently smaller in diameter than the internal cavity of the clicking capsule, to facilitate sliding contact with each other and the internal ends of the capsule without stacking. The metal clicking elements may be typically shaped of metal such as copper, aluminum and steel. In a first preferred embodiment, transparent clicking capsules, typically constructed of glass vials or tubing are inserted in the bodies of flexible plastic lures such as simulated grubs, worms, crawfish and the like, such that retrieval of the flexible plastic lures through a waterbody causes the lures to emit a clicking sound as the clicking elements slide back and forth in the shell cavity of the clicking capsule, striking each other and the internal ends of the capsule, to emit the desired fish-attracting clicking noise.
In another preferred embodiment of the invention a metal clicking capsule is provided, which includes a metal capsule tube closed at one end and plugged at the opposite end to contain one or more clicking elements therein. The metal clicking capsule is typically attached by a clip, tape or other device to either the hook or wire harness of various types of fishing lures such as jigs, spinner baits and the like, to facilitate emission of a clicking noise when these lures are retrieved through a waterbody. In one embodiment the metal clicking capsule plug or tube is fitted with a clip for removable attachment to the hook or spinner bait harness and in another embodiment the clicking capsule can be taped, glued or otherwise attached to the hook or spinner harness, according to the knowledge of those skilled in the art.
One of the most significant innovations in recent years in the fishing industry is that of providing fishing lures with capsules containing lead or steel shot to effect a rattling action when the lure is retrieved. These capsules have been embedded in the body of the lure, attached to the lure by various means and otherwise used to facilitate a rattling noise as the lure is retrieved through a waterbody. The resulting attraction to game fish is well documented in larger catches, bigger fish and more action than is possible with lures not having the rattling action. Typical of the "rattling" lures is the "Fishing Lure Sound Producer" detailed in U.S. Pat. No. 3,988,851, dated Nov. 2, 1976, to Sacharnoski, Sr. The capsule includes a glass tube with closed, sealed ends and containing multiple free spherical balls, preferably metal, for association with a fishing lure, to produce clear, resonant sounds that attract fish to the lure without materially affecting the attitude of the lure or its course through the water. Another fishing lure sound-producer is detailed in U.S. Pat. No. 4,203,246, dated May 20, 1980, also to Sacharnoski. The capsule includes a glass tube with closed ends and containing multiple free spherical balls, preferably metal, for association with the fishing lures to roll in the capsule and produce clear resonant sounds that attract fish to the lure in its course through the water. U.S. Pat. No. 4,747,228, dated May 31, 1988, to Jay Giovengo, Jr., details a fishing lure in which at least one steel ball rolls in a closed, hollow container and the container is disposed in proximate relationship to a hook, such that when the assembly is moved through water, the movement of the steel balls in the cylinder generates a noise that attracts the fish. U.S. Pat. No. 4,791,750, dated Dec. 20, 1988, to R. M. Gammill, details a "Fishing Lure With Internal Rattle". The fishing lure includes a molded lure body such as a lead jig head, in a non-magnetic cylinder or capsule provided with at least one non-magnetic ball therein, the capsule inserted in a cavity provided in the jig head, in order to produce a sound of desired intensity and resonance and attract fish when the fishing lure is retrieved. A "Rattling Fishing Lure" is detailed in U.S. Pat. No. 5,001,856, dated Mar. 26, 1991, to Don Gentry. The fishing lure has a rattling device which includes an elongated capsule of synthetic resin material containing noise makers and having a cap which also serves to secure the capsule to the lure. The exterior of the capsule is exposed to the water in which the lure is immersed, to optimally transmit noise from the rattle to the water for attracting fish. U.S. Pat. No. 5,018,297, dated May 28, 1991, to Michael B. Kennedy, Jr., details an "Audible Fishing Lure" which includes a fish-attracting rattling skirt assembly. The skirt assembly includes a noise-making subassembly characterized by a hollow housing, an object enclosed within the hollow housing for generating fish-attracting audible noises, the first hollow, resilient tube having an outer wall and an inner diameter allowing insertion and retention of the hollow housing into the first hollow, resilient tube, a second hollow, resilient tube having an outer wall and open ends having open-ended space within its inner wall unoccupied and reserved for allowing adaptation to the fishing lure and the fish-attracting, undulation skirt.
It is an object of this invention to provide clicking capsules for fishing lures, which capsules are characterized by a hollow interior or cavity fitted with at least one elongated, generally cylindrical body having a bevelled, rounded or blunt end for contacting the ends of the capsule and making a clicking noise when the lure in which the capsule is inserted is retrieved through a waterbody.
Another object of the invention is to provide transparent clicking capsule for insertion in fishing lures, which clicking capsule includes at least one clicking element slidably disposed in the interior of the capsule for emitting a clicking noise when the capsule is inserted in the lure and the lure is retrieved through a waterbody.
Still another object of this invention is to provide plugged metal clicking capsules for receiving one or more elongated metal clicking elements that are slidably disposed in the capsule, wherein the capsules are inserted in fishing lures and contact each other and the capsules, to emit a clicking noise when the fishing lures are retrieved through a waterbody.
Still another object of this invention is to provide new and improved glass, plastic and metal clicking capsules for receiving one or more generally cylindrical metal clicking elements of the same or different diameter, having blunt or squared, tapered or bevelled ends, the clicking elements being slidably disposed inside the clicking capsules for emitting a clicking noise when the clicking capsules are inserted in the body of flexible plastic or hard body fishing lures and the lures are retrieved through a waterbody.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in new and improved clicking capsules for fishing lures, which clicking capsules may be constructed of such materials as glass, plastic or metal and incorporate one or more elongated, sliding, wire clicking element segments having a selected diameter which is less than the internal diameter of the capsules, the clicking elements further characterized by bevelled, rounded or blunt ends, to optimize the clicking effect manifested when the clicking capsules are inserted in the hard or soft body portions of fishing lures and the fishing lures are retrieved through a waterbody.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by referenced to the accompanying drawing, wherein:
FIG. 1 is a perspective view, partially in section, of a transparent glass or plastic clicking capsule of this invention, with a pair of cylindrical clicking elements slidably disposed therein;
FIG. 2A is a side view of a set of bevelled clicking elements for disposition inside the clicking capsule illustrated in FIG. 1;
FIG. 2B is a side view of another set of oppositely-bevelled clicking elements;
FIG. 2C is a side view of still another set of clicking elements, each having a different diameter, a bevelled end and a squared or blunt end;
FIG. 2D is a side view of another set of clicking elements, each having a bevelled end and a rounded end;
FIG. 2E is a side view of a set of three clicking elements of varying diameter having facing bevelled ends and opposite bevelled ends;
FIG. 3 is a side sectional view of the transparent clicking capsule illustrated in FIG. 1, more particularly illustrating three clicking elements having various end configurations, provided in the clicking capsule;
FIG. 4 is a perspective view of the head and upper body portion of a flexible plastic grub lure, illustrating a preferred insertion of the transparent clicking capsule illustrated in FIGS. 1 and 3 into the grub body;
FIG. 5 is a partial sectional view of the flexible plastic grub illustrated in FIG. 4, more particularly illustrating the transparent clicking capsule fully inserted and embedded in functional configuration in the grub body;
FIG. 6 is a side view, partially in section, of a preferred plugged metal clicking capsule with two clicking elements having blunt end configurations provided therein;
FIG. 7 is an enlarged perspective view of the plug element of the metal clicking capsule illustrated in FIG. 6;
FIG. 8 is a perspective view of a typical capsule clip for securing the metal clicking capsule illustrated in FIG. 6 to a spinner bait or jig harness or hook;
FIG. 9 is a perspective view, partially in section, of a typical jig lure with the metal clicking capsule illustrated in FIG. 6 embedded therein;
FIG. 10 is a sectional view taken along line 10-10 of the jig lure illustrated in FIG. 9, more particularly illustrating embedment of the metal clicking capsule in the body thereof;
FIG. 11 is a perspective view, partially in section, of a jig lure with the metal jig capsule illustrated in FIG. 6 clipped to the jig hook;
FIG. 12 is a side view of a spinner bait lure with the metal clicking capsule illustrated in FIG. 8 attached to the wire harness of the spinner bait lure by means of the capsule clip;
FIG. 13 is a perspective view of a flexible plastic worm with a pair of the transparent clicking capsules illustrated in FIGS. 1 and 3 embedded in tandem therein; and
FIG. 14 is a top view, partially in section, of a flexible plastic crawfish having a transparent clicking capsule containing two clicking elements embedded therein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1-3 of the drawings, the transparent clicking capsule of this invention is generally illustrated by reference numeral 1. The transparent clicking capsule 1 is characterized by a small, elongated glass tube, vial or ampoule that has closed ends. In a most preferred embodiment, the tube or capsule shell 2 of the transparent clicking capsule 1 is drawn from hard glass tubing such as commercially available "Pyrex" (trademark) glass. Accordingly, the shell ends 3 normally protrude pursuant to the glass drawing effect, as illustrated in FIGS. 1 and 3. A shell cavity 4 is formed in the capsule shell 2 and one or more elongated, generally cylindrical clicking elements 5 are inserted in the shell cavity 4 before the shell ends 3 are heat-sealed. Accordingly, after the shell ends 3 are sealed as illustrated in FIGS. 1 and 3, the clicking elements 5 are free to slide end-to-end inside the shell cavity 4 between the shell ends 3 and strike the closed ends of the shell cavity 4 and each other, in the case of more than one clicking element 5, to emit the desired fish-attracting clicking noise.
As illustrated in FIGS. 2A-2E, the clicking elements 5 are characterized by a generally cylindrically-shaped metal body 6, having either rounded ends 7, bevelled ends 8, or blunt ends 9, or the like, which rounded ends 7, bevelled ends 8 and blunt ends 9 may be similar or dissimilar for any selected clicking element 5. For example, in FIGS. 2A and 2B the cylindrical bodies 6 of the two clicking elements 5 are both characterized by bevelled ends 8 which match each other as the clicking elements 5 slide back and forth inside the capsule shell 2 of a transparent clicking capsule 1. Similarly, as illustrated in FIG. 1, the clicking elements 5 are characterized by blunt ends 9, which likewise strike each other and the ends of the shell cavity 4 when the clicking elements 5 are caused to slide linearly inside the shell cavity 4. Furthermore, referring to FIG. 3, the clicking elements 5 may be of dissimilar length and may also be fitted with facing rounded ends 7, bevelled ends 8 and blunt ends 9, as illustrated. Moreover, as illustrated in FIGS. 2C and 2D, the clicking elements 5 may be of dissimilar length and diameter and may have facing rounded ends 7 or blunt ends 9 and opposite bevelled ends 8, as illustrated. As further illustrated in FIG. 2E, the clicking elements 5 may be characterized by facing bevelled ends 8 and opposite bevelled ends 8. Additionally, as illustrated in FIG. 6, the clicking elements 5 may be characterized by a rounded end 7 that faces a blunt end 9 inside the shell cavity 4 of a metal clicking capsule 10 and may have opposite blunt ends 9 and rounded ends 7, as illustrated. Accordingly, it will be appreciated by those skilled in the art that the clicking element or elements 5 which may be placed in the shell cavity 4 of the capsule shell 2 of both the transparent clicking capsule 1 and the metal clicking capsule 10 may be generally cylindrical in cross-sectional configuration, thus having a cylindrical body 6, but may have a diameter of selected size and may be provided with either rounded end 7, bevelled end 8 or blunt ends 9, in any desired combination. In a most preferred embodiment of the invention the ends of the clicking elements 5 which face the shell ends 3 of the capsule shell 2 inside the shell cavity 4 of the transparent clicking capsule 1 are characterized by bevelled ends 8, since this configuration of the clicking elements 5 better fits the interior end configuration of lure shell cavity 4 and has proved to emit a louder clicking sound than the clicking elements 5 having rounded ends 7 or blunt ends 9. Accordingly, optimum clicking noises emitted from the transparent clicking capsule 1 are those due to one or more clicking elements 5 which are characterized by rounded ends 7, bevelled ends 8 or blunt ends 9 that face each other and opposite bevelled ends 8 that strike the internal ends of the shell cavity 4 of the capsule shell 2.
Referring now to FIGS. 4 and 5 of the drawings, in functional use, the transparent clicking capsule 1 is inserted in the flexible plastic grub body 18 of a flexible plastic grub 17 in the manner indicated in FIG. 4. The flexible plastic grub 17 typically has a grub tail 19 extending from the grub body 18 and is a popular lure for taking such fish as black bass. FIG. 5 illustrates complete embedment of the transparent clicking capsule 1 inside the grub body 18 in functional configuration, such that mounting of the grub body 18 on a hook assembly or jig head (not illustrated) allows retrieval of the flexible plastic grub 17 through a waterbody in conventional fashion, according to techniques well known to those skilled in the art. This retrieval causes the two clicking elements 5 located inside the shell cavity 4 of the capsule shell 2 of the transparent clicking capsule 1 to slide linearly, strike each other and the ends of the capsule shell 2 with each pull or twitch of the grub 17, and emit the desired clicking noise as the lure is retrieved.
Referring to FIGS. 6-11 and initially to FIGS. 6 and 7 of the drawings, in another preferred embodiment of the invention the metal clicking capsule 10 is characterized by a capsule tube 11, which is closed at one end and is sealed with a plug 12 at the opposite end to maintain two clicking elements 5 inside the tube cavity 13 of the capsule tube 11. The plug 12 may include an integral capsule clip 14, which has a clip opening 15 that communicates with a clip slot 16 in the capsule clip 14. Thus, the capsule clip 14 can be engaged with the hook 40 of a jig lure 34 to mount the metal clicking capsule 10 on the jig lure 34, as illustrated in FIG. 11. Accordingly, like the transparent clicking capsule 1 illustrated in FIGS. 1 and 8, the metal clicking capsule 10 can be mounted on the hook 40 or embedded in the jig lure body 35 of a jig lure 34 as illustrated in FIGS. 9-11 to facilitate a clicking action and noise from the clicking elements 5 as the jig lure 34 is retrieved. The jig lure 34 typically includes a line eye 36, receiving a line swivel 41 attached to the jig lure body 35, for attaching a fishing line 37, as well as a skirt flange 38 and the hook 40, which are hidden by a skirt 39. Insertion of the clicking elements 5 in the capsule tube 11 of the metal clicking capsule 10 is easily effected and closure of the capsule tube 11 by inserting the plug 12 is easily accomplished to seal the clicking elements 5 in the tube cavity 13 of the metal clicking capsule 10.
In yet another preferred embodiment of the invention, referring to FIGS. 8 and 12 of the drawings, the metal clicking capsule 10 is provided with a capsule clip 14 of different design from the capsule clip 14 provided on the plug 12. The capsule clip 14 has a clip slot 16 which receives the spinner harness 44 of a spinner bait lure 42, to facilitate interaction of the clicking elements 5 and emission of a clicking noise from the metal clicking capsule 10 when the spinner bait lure 42 is retrieved by means of line 37, tied to the line eye 36 by means of the line swivel 41. The spinner bait lure 42 is typically characterized by a solid, usually lead, spinner bait lure body 43 and a spinner 45 is rotatably attached to the spinner harness 44 by means of a spinner swivel 46.
Referring now to FIG. 13 of the drawings, a flexible plastic worm 21 is illustrated, with an elongated worm body 22, terminating in a worm tail 23. A pair of transparent clicking capsules 1 are inserted in tandem relationship in the worm body 22 in the same manner as that illustrated with respect to the flexible plastic grub 17, illustrated in FIG. 5 of the drawings. Accordingly, the transparent clicking capsules 1 in the flexible plastic worm 21 emit approximately twice the clicking intensity of a single transparent clicking capsule 1 as the flexible plastic worm 21 is mounted on a hook assembly or jig head (not illustrated) and retrieved through a waterbody.
Similarly, referring to FIG. 14 of the drawings, a flexible plastic crawfish 25 is illustrated, having a crawfish body 26, terminated by a crawfish tail 27 and also having simulated feelers 28 and claws 29. A hook 30 is embedded in the crawfish 27 and includes a hook eye 31, to which is attached a line 37 and fitted with a weed guard 32. A transparent clicking capsule 1 is embedded in the crawfish body 26 of the flexible plastic crawfish 25 in the same manner as that illustrated in FIG. 5 with respect to the flexible plastic grub 17. Retrieval of the flexible plastic crawfish 25 through a waterbody by means of the hook 30 or a suitable hook assembly or jig head (not illustrated) therefore causes the clicking elements 5 located in the capsule shell 2 of the transparent clicking capsule 1 to emit a clicking noise as the clicking elements slide linearly and strike each other, as well as the ends of the capsule shell 2.
It will be appreciated by those skilled in the art that the shape, size (length and diameter) and character of the clicking elements 5 placed in either the transparent clicking capsule 1 or the metal clicking capsule 10 may vary, depending upon the desired quality and intensity of sound which is to be emitted from the respective capsule shell 2 and capsule tube 11. Accordingly, a single clicking element 5 of relatively large diameter may be provided in the capsule shell 2 and capsule tube 11, respectively, under circumstances where a more pronounced, lower pitched clicking noise is emitted from the transparent clicking capsule 1 and the metal clicking capsule 10, respectively. A higher pitched clicking noise can be accomplished by using multiple smaller clicking elements 5 in the respective capsule shell 2 and capsule tube 11, as illustrated in FIGS. 2A-2E, respectively. Furthermore, the ends of each respective clicking element 5 may be shaped to define a rounded end 7, a bevelled end 8 and/or a blunt 9 to further define the nature and character of the sound emitted from the transparent clicking capsule 1 and the metal clicking capsule 10.
It will be further appreciated by those skilled in the art that, as described above, the diameter of the respective clicking elements 5 may be the same or different in any desired capsule. However, the clicking element diameter is most preferably chosen such that this diameter is less than the internal diameter of the capsule shell 2 which defines the shell cavity 4 in both the transparent clicking capsule 1 and the metal clicking capsule 10. There must be sufficient room in the shell cavity 4 of the capsule shell 2 and in the tube cavity 13 of the capsule tube 11, respectively, to facilitate linear sliding of the respective clicking elements 5 in the shell cavity 4 and tube cavity 13 in end-to-end relationship. However, the diameter or diameters of the respective clicking elements 5 should be sufficiently large to prevent stacking or overlapping of the clicking elements 5 in the respective shell cavity 4 and tube cavity 13, to insure that the clicking elements 5 always move linearly in tandem or linearly-aligned relationship to facilitate optimum noise emission from the transparent clicking capsule 1 and the metal clicking capsule 10, respectively.
The quality and nature of sound emitted from the respective transparent clicking capsule 1 and metal clicking capsule 10 are further defined and adjusted by the nature of the clicking elements 5. For example, the more dense clicking elements 5 which are constructed of steel, yield a clicking noise of different character from clicking elements 5 which are constructed of the lighter metals, aluminum and copper, for example. This factor can also be used to construct a transparent clicking capsule 1 and metal clicking capsule 10 having a clicking noise of selected intensity and character when coupled with the shaping of the individual clicking elements 5, to define either rounded ends 7, bevelled ends 8 and/or the blunt ends 9 or otherwise shaped clicking elements 5. Furthermore, the clicking noise variation can be also adjusted by choosing the size and number of clicking elements 5 located in the shell cavity 4 and tube cavity 13 of the respective capsule shell 2 and capsule tube 11, respectively.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made in the invention and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention.
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Clicking capsules for fishing lures, which capsules may be constructed of plastic, glass and metal and encapsulate one or more elongated clicking elements. The clicking elements are typically constructed of metal wire such as copper, aluminum and steel and are generally cylindrical with varying diameter and rounded, blunt, or bevelled ends, to enhance the clicking effect when the clicking elements slide and strike the ends of the capsules, as well as each other. The clicking capsules may be inserted in flexible plastic fishing lures such as simulated grubs, worms, crawfish and the like and may also be inserted in cavities provided in the hard bodies of such fishing lures as jigs, "crank baits", top water lures and the like. Furthermore, the clicking capsules can be fitted with clips or otherwise attached to the wire harness of spinner bait lures or to the hooks of jigs and other lures to effect the desired clicking noise when the lures are retrieved.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is based on and claims priority from Japanese Patent Application 2005-366973, filed Dec. 20, 2005, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a signal processing circuit of a rotation detecting device that obtains data about rotation of a rotating object, such as the rotation position, the rotation speed and/or the rotation direction of the rotating object.
[0004] 2. Description of the Related Art
[0005] As shown in FIG. 6 , a common rotation detection device includes a pair of magnetic sensors 1 , 2 , a magnetic rotor 80 that rotates with a rotating object and a signal processing circuit 100 . The magnetic rotor 80 has a plurality of teeth having mountains 80 a and valleys 80 b . The processing circuit 100 is constituted of a rotation data forming section 101 , a rotation direction detecting section 102 and a masking section 103 . When the magnetic rotor 80 rotates, the magnetic sensors 1 , 2 provide rotation signals Sa and Sb, which are inputted to the processing circuit 100 . Thus, the data about the rotation of the rotating object are obtained.
[0006] As shown in FIG. 7 , the rotation data forming section 101 provides a rectangular signal whose level changes in synchronism with the rising edge of the rotation signal Sa or Sb when the magnetic rotor 80 rotates in a normal direction. When the rotation direction of the rotating object changes from one direction to the other direction, the rotation direction detecting section 102 detects the change of the direction by change in the phase-relationship between the rotation signals Sa and Sb. Then, the masking section 103 masks the first edge after the change of the rotation direction to obtain an output signal OUT 1 that has the same pulse width or duty ratio as the rotation signal Sa, as long as the duty ratio is about 50% or higher.
[0007] However, if the duty ratio of the rotation signals Sa, Sb is as low as about 25% as shown in portion (a) of FIG. 8 , the output signal OUT 1 after the masking may be reversed as shown in portion (b) of FIG. 9 , resulting in that the output signal OUT 1 has an entirely different duty ratio. If, for example, the rotation detecting device is set to an engine, the position of the crankshaft of an engine can not be accurately detected.
SUMMARY OF THE INVENTION
[0008] Therefore, an object of the invention is to provide an improved signal processing circuit with a rotation detecting device.
[0009] Another object of the invention is to provide a rotation detecting device that can detect accurate rotation data that include the duty ratio of a rotation signal.
[0010] According to a feature of the invention, a signal processing circuit a rotation detecting device includes a reversal signal forming means for providing a bi-level reversal signal (Rev) changing from one level to the other in response to a change of rotation direction of a rotor, a level-change-prohibiting section for forming a level-change prohibiting signal (Ce) to mask a first rotation signal (Sa) during one pulse width from the first rising edge to the first falling edge after the change of the rotation direction of the rotor is detected and a rotation data processing means for forming a triple level output signal (OUT 2 ) having triple-level pulses that synchronize with the pulses of the first rotation signal (Sa) except for first one of the pulses being masked after each change of the rotation direction and change voltage level from one level to another when the rotation direction changes one direction to the other direction.
[0011] In the above signal processing circuit, the rotation sensing unit preferably includes a first rotation sensors for providing the first rotation signal (Sa) and a second rotation sensor for providing a bi-level second rotation signal (Sb) in response to rotation of the rotor at a phase different from the first rotation signal. In this case, the reversal signal forming means includes a reversal signal detecting section for detecting a change of rotation direction by a change in phase of the first rotation signal (Sa) relative to the second rotation signal (Sb). The reversal signal forming means further includes a reversal signal forming section for providing a bi-level reversal signal (Rev) according to direction of rotation of the rotor.
[0012] In addition, the rotation data processing means may include an edge detecting section for detecting edges of the first rotation signal (Sa), a first output signal forming section for forming a bi-level first output signal (OUT 1 ) having pulses that synchronize with the pulses of the first rotation signal (Sa) except for one pulse being masked right after each change of the rotation direction and a rotation data processing section for forming the triple level second output signal (OUT 2 ) based on the first bi-level output signal (OUT 1 ) and the reversal signal (Rev).
[0013] A rotation detecting device having the above signal processing circuit may include as the rotor a magnetic disk having teeth on the periphery thereof and as the first and/or second rotation sensors a magnetic sensor disposed opposite the magnetic disk. Such a rotation detecting device may include a rotary disk having a plurality of slits on the periphery thereof as the rotor; and a light emitting diode and a photo transistor disposed opposite said rotary disk.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other objects, features and characteristics of the present invention as well as the functions of related parts of the present invention will become clear from a study of the following detailed description, the appended claims and the drawings. In the drawings:
[0015] FIG. 1 is a circuit diagram of a signal processing circuit of a rotation detecting device according to a preferred embodiment of the invention;
[0016] FIG. 2 is a time chart showing signals at various portions of the signal processing circuit of the rotation detecting device according to the preferred embodiment;
[0017] FIG. 3 is a table showing operating conditions of main portions of the signal processing circuit of the rotation detecting device according to the preferred embodiment;
[0018] FIG. 4 is a time chart showing at main portions of the signal processing circuit;
[0019] FIG. 5 is a schematic diagram showing a main portion of the rotation detecting device of the rotation detecting device according to the preferred embodiment;
[0020] FIG. 6 is a block diagram showing a prior art signal processing circuit;
[0021] FIG. 7 is a time chart showing a relationship between a rotation signal having a higher duty ratio and the output signal of the prior art signal processing circuit; and
[0022] FIG. 8 is a time chart showing a relationship between a rotation signal having a lower duty ratio and the output signal of the prior art signal processing circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] A signal processing circuit of a rotation detecting device according to a preferred embodiment of the present invention will be described with reference to the appended drawings.
[0024] As shown in FIG. 1 , the signal processing circuit 100 is constituted of a reversal detecting section 10 connected to a first magnetic sensor 1 and a second magnetic sensor 2 , an edge detecting section 20 , a level-change-prohibiting section 30 , an output signal forming section 40 , a reversal signal forming section 50 and a rotation data processing section 60 .
[0025] The reversal detecting circuit 10 includes a pair of D-flip-flop circuits 11 and 13 , an inverter 14 connected to a Q-terminal of the second D-flip-flop circuit 13 , a NOR circuit 15 , a NAND circuit 16 , an exclusive (Ex) OR circuit 17 , a NAND circuit 18 , etc.
[0026] The reversal detecting section 10 detects a reversal of the rotor 80 by a change in the phase of the first rotation signal Sa relative to the second rotation signal Sb. The edge detecting section 20 detects all the edges of the first rotation signal Sa. The level-change-prohibiting section 30 provides a level-change prohibiting signal Ce to prohibit the level change of the signal inputted thereto in synchronism with the first rising edge and the first falling edge of the first rotation signal Sa after detection of the reversal by the reversal detecting section 10 . The output signal forming section 40 masks the first pulse of the signal inputted thereto after detection of the reversal according to the level-change-prohibiting signal Ce to provide a signal OUT 1 that includes information of the reversal of the rotor 80 .
[0027] The above operation of the signal processing circuit will be described in more detail with reference to FIGS. 1 and 2 .
[0028] The first rotation signal Sa is inputted from the first magnetic sensor 1 to a clock terminal of the first D-flip-flop circuit 11 of the reversal detecting section 10 and to a clock terminal of the second D-flip-flop circuit 13 thereof via an inverter 12 , and the second rotation signal Sb is also inputted from the second magnetic sensor 2 to D-terminals of the first and second D-flip-flop circuits 11 , 13 , as shown in (a) and (b) of the time chart shown in FIG. 2 .
[0029] The first D-flip-flop circuit 13 provides output signal Q 1 , as shown in (c), in which the preceding rising edge of the first rotation signal latches the logical level of the second rotation signal Sb in the normal rotation. That is, level “0” is maintained at the normal rotation, and level “1” is maintained at the reversed rotation.
[0030] The second D-flip-flop circuit 13 provides via the inverter 14 a second output signal Q 2 B, as shown in (d), in which the preceding falling edge of the first rotation signal Sa latches the logical level of the second rotation signal Sb in the normal rotation. That is, level “ 0 ” is maintained at the normal rotation, and level “ 1 ” is maintained at the reversed rotation. However, the level change of the second output signal Q 2 B is retarded by one pulse of the first rotation signal Sa from the level change of the first output signal Q.
[0031] Signals Qm 1 , Qm 2 shown in (f) and (g) are respectively the output signals of the NOR circuit 15 and the NAND circuit 16 . The Ex OR circuit 17 has input terminals respectively connected to the output terminals of the NOR circuit 15 and the NAND circuit 16 and provides a reversal detection dignal Ra as shown in (h) of FIG. 2 . The reversal detection dignal Ra rises up when the first rotation signal Sa rises up right after the reversal of the rotor 80 shown in FIG. 8 and falls down just when the first rotation signal Sa first falls down.
[0032] The signals Qm 1 , Qm 2 are sent to the NAND circuit 18 to form an output signal Rb, as shown in (o) of FIG. 2 . The signal Rb rises up just when the first rotation signal Sa rises up after the rotation direction of the rotor 80 changes from a normal direction to the reversed direction and falls down after the rotation direction of the rotor 80 changes from the reversed direction to the normal direction.
[0033] The edge detecting section 20 includes a delay circuit 21 connected with the first magnetic sensor 1 and an exclusive (Ex) OR circuit 22 has input terminals respectively connected with the first magnetic sensor 1 and the delay circuit 21 .
[0034] The delay circuit 21 delays the first rotation signal Sa by about 10 microseconds, and the Ex OR circuit 22 provides a clock signal CLKa having the pulse width of 10 microseconds, as shown in (e) of FIG. 2 . This clock signal CLKa synchronizes with all the rising and falling edges of the first rotation signal Sa.
[0035] The level-change-prohibiting section 30 includes a delay circuit 31 , a D-flip-flop circuit 32 and a NOR circuit 33 that has a pair of input terminals respectively connected with the delay circuit 31 and the Q terminal of the D-flip-flop circuit 32 .
[0036] The delay circuit 31 delays the reversal detection dignal Ra by about 5 microseconds to provide a delay signal RaD as shown in (i). The D-flip-flop circuit 32 has a D-terminal connected with the delay circuit 31 and a clock terminal connected to the Ex OR circuit 22 to latch the delay signal RaD in synchronism with the rising edge of the clock singal CLKa, thereby providing a latch signal RaS that delays from the reversal detection signal Ra by one pulse thereof, as shown in (j) of FIG. 2 . The NOR circuit 33 provides “0” level of the level-change prohibiting signal Ce while the level of the delay signal RaD or the latch signal RaS is “1”, as shown in (k) of FIG. 2 .
[0037] The output signal forming section 40 includes delay circuits 41 , 42 , a NAND circuit 43 , an inverter 44 and a D-flip flop circuit 45 . The output signal forming section 40 provides an output signal OUT 1 whose pulses synchronize with the pulses of the first rotation signal Sa except for one pulse being masked right after each change of the rotation direction is detected.
[0038] The delay circuit 41 is constituted of about ten (10) series-connected inverters to delay the signal Ce by about 2 microseconds and filter the signal Ce to remove a steepled wave voltage of it. The delay circuit 42 is constituted of about twenty (20) series-connected inverters to delay the clock signal CLKa by about 10 microseconds to form a clock signal CLKb, as shown in (1) of FIG. 2 . A series circuit of the NAND circuit 43 and the inverter 44 forms a clock signal CLKc, as shown in (m) of FIG. 2 , which is inputted to a clock terminal of the D-flip-flop circuit 45 to provide the signal OUT 1 , as shown in (n) of FIG. 2 . The signal OUT 1 has “1” level signals that synchronize with the pulses of the first rotation signal Sa except for one pulse being masked right after the change of the rotation direction is detected.
[0039] Incidentally, the clock signal CLKc does not appear as long as the level of the level-change prohibiting signal Ce is “0”. The level-change prohibiting signal Ce also prohibits the clock signal CLKc while the rotation direction of the rotor 80 frequently changes in a chattering operation, as indicated by CT in FIG. 2 . Accordingly, generation of abnormal pulses can be prevented.
[0040] The reversal signal forming section 50 includes an inverter 51 , a NOR circuit 52 and an inverter 53 . The reversal signal forming section 50 provides a reversal signal Rev.
[0041] The inverter 51 provides the inverted signal CeDB of the output signal of the Delay circuit 41 , as shown in (p) of FIG. 2 . The NOR circuit 52 has input terminals respectively connected to the inverter 51 and the NAND circuit 18 . The series circuit of the NOR circuit 52 and the inverter 53 forms the reversal signal Rev, which is shown in (q) of FIG. 2 . When the rotor 80 rotates in the normal direction, the level of the reversal signal is “0”, while the level of the reversal signal is “1” when it rotates in the other direction.
[0042] The rotation data processing section 60 includes inverters 61 , 63 , 65 , NAND circuits 62 , 64 , resistors R 1 , R 2 , transistors Tr 1 , Tr 2 and a DC power source connected to an end of the resistor R 1 . The rotation data processing section 60 provides a triple level signal OUT 2 whose level changes as the rotation direction of the rotor 80 changes.
[0043] The NAND circuit 62 has input terminals respectively connected to the D-flip-flop circuit 45 and the inverter 53 via the inverter 61 , and the NAND circuit 64 has input terminals respectively connected to the D-flip-flop circuit 45 and the inverter 53 . The NAND circuit 62 controls the transistor Tr 1 via the inverter 63 , and the NAND circuit 64 controls the transistor Tr 2 via the inverter 65 . Therefore, the transistors Tr 1 , Tr 2 turn on or off to provide the signal OUT 2 , which is shown in FIGS. 3 and 4 . The signal OUT 2 has three levels, that is, H (high level), L (low level) and M (middle level).
[0044] When the rotor 80 rotates in the normal direction, the level of the reversal signal Rev is “0”, as shown in (q) of FIG. 2 or 4 . In the meantime, the level of the output signal OUT 2 of the rotation data processing section 60 becomes “H” as long as the level of the signal OUT 1 is “0”, and the level of the output signal OUT 2 becomes “L” as long as the level of the signal OUT 1 is “1”, as shown in (n), (q), (r) of FIG. 4 . When, on the other hand, the rotor 80 rotates in the reversed direction, the level of the reversal signal Rev is “1”. In the meantime, the level of the output signal OUT 2 of the rotation data processing section 60 becomes “H” as long as the level of the signal OUT 1 is “0”, and the level of the output signal OUT 2 becomes “M” as long as the level of the signal OUT 1 is “1”. Thus, the output signal OUT 2 changes its level when the rotation of the rotor 80 changes from one direction to the other.
[0045] Even if the duty ratio of the rotation signal Sa becomes as low as 25%, the output signals OUT 1 , OUT 2 provide the same duty ratio or logical level transition as the rotation signal Sa.
[0046] The arrangement of magnetic rotor 80 and the magnetic sensors 1 , 2 shown in FIG. 6 may be replaced by an optical rotary encoder. The rotary encoder includes a rotary disk 90 having a plurality of slits 90 a , a shaft 91 , a pair of photo-transistors 92 a , 92 b disposed at one side of the rotary disk 90 , a light emitting diode 93 with a magnifying glass 94 and amplifiers 95 a , 95 b.
[0047] When a light is emitted from the light emitting diode 93 , the light is magnified by the magnifying glass 94 . The magnified light passes through the slits 90 a and received by the phototransistors 92 a , 92 b , which convert the light into electric signals. The amplifiers 95 a , 95 b amplify the electric signals to form the rotation signals Sa and Sb, which are different in phase from each other. These signals are inputted to the reversal detecting section 10 to obtain the output signal OUT 1 and/or the output signal OUT 2 in the same manner as described above.
[0048] In the foregoing description of the present invention, the invention has been disclosed with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made to the specific embodiments of the present invention without departing from the scope of the invention as set forth in the appended claims. Accordingly, the description of the present invention is to be regarded in an illustrative, rather than a restrictive, sense.
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A rotation detecting device includes a rotation detecting unit for providing first and second rotation signals in response to rotation of a rotating object and a signal processing circuit for processing the signals to provide rotation data such as the rotation direction, rotation speed and rotation position. The signal processing circuit includes a reversal signal forming circuit for providing a reversal signal changing in response to a change of the rotation direction, a level-change-prohibiting section for forming a level-change prohibiting signal to mask the first rotation signal during one pulse width from the first rising edge to the first falling edge after the change of the rotation direction of the rotor is detected, and a rotation data processing circuit for forming from the reversal signal and the level-change prohibiting signal a signal having triple-level pulses that synchronize with the pulses of the first rotation signal except for first one of the pulses being masked after each change of the rotation direction and change voltage level when the rotation direction changes.
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BACKGROUND OF THE INVENTION
This invention relates to a driving technique for driving panels and more particularly to a method for driving a liquid crystal display panel of the DTN type that is, combined DS (dynamic scattering mode) and TN (twisted nematic mode) type, which has a twisted alignment at 90° with respect to a polarizer and a detector for the purpose of displaying various moving pictures including characters and symbols, for example.
When it is desirable to display moving pictures such as TV pictures by means of a matrix configuration liquid crystal display panel, it is necessary to provide half tone. In the case where those pictures are to be displayed on the matrix liquid crystal panel by the well known pulse width modulation technique, frequency components of voltage waveforms developing on the panel include higher frequency components. On the other hand, for a whole black level display (OFF state) or a whole white level display (ON state), low frequency components are significant. Therefore, in displaying the moving pictures, more particularly ones including a number of black level pixels or white level pixels on the liquid crystal panel, the low frequency components are increased with the result in deterioration in image quality on the liquid crystal panel.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method for driving a display panel which minimizes variations in threshold level due to low frequency component, avoids inferior molecular alignment and extends the operating life of the display panel.
In accordance with a preferred aspect of the present invention, a display device comprises a dynamic scattering mode liquid crystal structure including at least one first display electrode in a first direction and a plurality of second display electrodes in a second direction, means for supplying said plurality of second display electrodes with a plurality of scanning signals of sequentially shifted phases with polarity inverted in a predetermined interval of time, means for supplying said first display electrode with frame signals indicative of information to be displayed and having polarity inverted in said predetermined interval, wherein a plurality of pulse signals having a pulse width shorter than the pulse width of said scanning signals are added to said frame signals.
BREIF 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 illustration of a DS liquid crystal cell;
FIG. 2 diagrammatically illustrates a DTN cell structure incorporating the DS cell of FIG. 1;
FIG. 3 is a graph showing the voltage-transmission light intensity properties of the DTN cell;
FIG. 4 is a perspective view partially in cross section of a matrix type liquid crystal display panel using the DTN cell structure;
FIGS. 5(a) to 5(e) are waveform diagrams of voltages applied to column and row electrodes and a particular one of pixels on the matrix type liquid crystal display panel;
FIGS. 6(a) to 6(h) are voltage waveform diagrams when all of the pixels on the panel are enabled or disabled;
FIG. 7 is a graph showing the threshold level-frequency properties of the DTN cell structure;
FIGS. 8(a) and 8(b) are frequency spectra of voltage waveforms on the matrix display panel;
FIG. 9 is a schematic block diagram of an embodiment of the present invention; and
FIGS. 10(a) to 10(f) are waveform diagrams of voltages appearing in the emobodiment of FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is an illustration of a DS liquid crystal cell which is of interest to the present invention. The liquid crystal cell 1 is adapted such that the logituninal axes of molecules on its upper and lower surfaces are pependicular to each other due to 90° twisted alignment (homogeneous alignment). The upper and lower surfaces of the liquid crystal cell 1 are covered with surfactants 2 which each overlying a layer 3 of SiO 2 and a transparent, electrically conductive layer 4. Furthermore, a layer 5 of SiO 2 and a glass sheet 6 are disposed on each of the transparent and conductive layers 4. The first SiO 2 layer 3 is to ensure uniform affinity between the transparent and conductive layers 4 and the surfactants 2, while the second SiO 2 layer 5 is to ensure uniform surface of the glass sheets 6. An example of conditions of manufacturing the DS cell as shown in FIG. 1 is depicted in Table 1.
TABLE 1______________________________________Liquid crystal Predominant liquid crystal materialmaterial p-methoxybenzylidene-p'-n-butylaniline 45 wt % p-ethoxybenzylidene-p'-n-butylaniline 45 wt % Additional liquid crystal material 1-cyano-1-(p-ethoxyphenyl)-2- (p-hexyphenyl)ethylene.sup.(1) 9.82% cholesteryl nonanoate.sup.(2)Ionic additive tetrabutylammonium-3-5-dinitrobenzoate 0.75 wt % with respect to liquid crystalAlignment SH 6040 (by Torei Silicone)agent CH.sub.2 CHCH.sub.2 OCH.sub.2 CH.sub.2 Si(OCH.sub.3).sub.3 1 wt %______________________________________ ##STR1## ##STR2##
FIG. 2 diagrammtically illustrates a typical example of a DTN cell structure incorporating the DS type cell of FIG. 1. One major surface of a DS cell is flanked with a polarizer 8 and a scattering plate 7 and another major surface with a detector 8'. The polarization direction of the polarizer 8 and the detector 8' is shown by the arrow. When light from a light source 11 is incident on the DTN cell after being scattered by the scattering plate 7, output light 12 is imaged as a function of brightness due to the property of canceling polarization light by the DS cell structure 10. In the situation shown in FIG. 2, the incident light is modified into linearly polarized light through the polarizer 8 and then twisted by 90° through the DS cell structure 10 having a 90° twisted alignment so that light is shut off and no output light 12 is obtainable since the alignment direction of the output side of the DS cell is normal to the polarization direction 9 of the detector 8'. In other words, the cell is in the OFF state.
When a certain voltage is applied to the transparent and conductive layer 4 of the DS cell 10, polarized light components passing through polarizer 8 along the polarization direction 9 are not subject to 90° rotation in traversing the DS cell 10 so that the output light 12 is obtainable through the detector 8'. In other words, the cell is in the ON state.
FIG. 3 shows a typical example of the voltage-transmission light intensity properties of the DTN cell structure of FIG. 2. In FIG. 3, the threshold voltage level is designated V th and the voltage at which the maximum intensity of transmission light is insured is designated V p . If the applied voltage is lower than the threshold level, then the DTN cell structure is in the OFF state and no light is transmitted. If the applied voltage varies within the range covering from the threshold level V th to the maximum voltage V p , a half tone image is provided. Furthermore, when the applied voltage is V p , the cell structure is placed into the ON state with a white level.
A matrix configuration liquid crystal display panel incorporating the DTN cell structure is typically shown in a partically cut-away perspective view of FIG. 4. The matrix panel of FIG. 4 includes a plurality of column electrodes 13 oriented in a first direction as one of the transparent and conductive layers 4 of the DS cell 10 of FIG. 1 and a plurality of row electrodes 14 oriented in a second direction as the other transparent conductive layer 4. Each of the crossings of the column electrodes 13 and the row electrodes 14 forms a respective pixel.
FIGS. 5(a) to 5(e) depict the waveform of a voltage applied to a particular column electrode 13 of the matrix panel of FIG. 4, the waveform of a voltage applied to a particular row electrode 14 and the waveform of a voltage applied to the crossing thereof. Modulating the brightness of the pixels of the matrix panel of FIG. 4 is achieved by varying the effective voltages on the pixels according to the information to be displayed. By way of example, the matrix panel is driven by line-sequential scanning with a 1/15 duty ratio. FIG. 5(a) shows a train of voltage pulses applied to the particular one x i of the column electrodes 13 to provide half tone, the voltage pulses being alternating pulses with a fixed amplitude V 1 . FIGS. 5(b) and 5(c) show scanning pulses applied to particular ones y j and y j+1 of the row electrodes 14, which pulses are alternating pulses with an amplitude V2. FIGS. 5(d) and 5(e) show the waveforms of the voltages applied across the pixels (y j -x.sub. i) and (y j+1 -x i ) of the liquid crystal panel. In this case the pixel (y j -x i ) is enabled with half tone and the pixel (y j+1 -x i ) is disabled.
FIGS. 6(a) to 6(h) show the waveforms of applied voltages to the matrix panel when all of the pixels are enabled or disabled. More particularly, FIG. 6(a) the waveform of a voltage signal applied to all of the column electrodes 13 when they are to be enabled. This voltage signal is inverted in polarity after a predetermined interval T so that the display panel is supplied with an alternating voltage. FIGS. 6(b) and 6(c) are the voltage waveforms showing the scanning pulses applied to the row electrodes y j and y j+1 , indicating that the display panel is supplied with an alternating voltage with polarity inverted in timed relationship with the signal waveform of FIG. 6(a). FIGS. 6(d) and 6(e) show the waveforms of voltages developing across the pixels (y j -x i ) and (y j+1 -x i ), indicating that all of the pixels are enabled (ON). FIG. 6(f) shows the waveform of a voltage signal applied to all of the column electrodes 13, wherein all of the pixels are disabled (OFF). This voltage signal is inverted in polarity after the predetermined interval T as in FIG. 6(a), thus supplying the liquid crystal panel with an alternating pulse. In FIGS. 6(g) and 6(h), there is shown the waveform of voltages developing across the pixels (y j -x i ) and (y j+1 -x i ) when the signal voltage as shown in FIG. 6(f) is applied. In this case the pixels are all disabled. Comparison of the voltage waveforms applied to the pixels as shown in FIGS. 5(d) and 5(e) and FIGS. 6(d), 6(e), 6(g) and 6(h) reveals that the former includes higher frequency components than that of the latter. Especially, the latter includes components of the basic interval 2 T and the liquid crystal panel is supplied many low frequency components with an interval T.
FIG. 7 is an example of the threshold voltage-frequency characteristics of the DTN cell structure. It is clear from FIG. 7 that the thresold voltage level of the DTN cell structure is somewhat higher within a low frequency range and a high frequency range. Variations in the threshold level result in variations in the effective voltage value V rms (OFF) of the liquid crystal display panel in the OFF state, thus deteriorating image quality and especially flicker effect on the display screen. Furthermore, the liquid crystal itself deteriorates when a voltage of a low frequency range is applied.
FIGS. 8(a) and 8(b) depict frequency spectra when a voltage is applied to the display panel. More particularly, FIG. 8(a) depicts when the voltage waveform of FIG. 5(d) is applied to the panel and FIG. 8(b) depicts when the voltage waveform of FIG. 6(d) is applied. The former shows higher intensities of the high frequency components and the latter shows higher intensities of the low frequency components.
As stated previously, a purpose of the present invention is to provide a driving technique for a display panel by which the variations in the threshold voltage level are minimized by adding a plurality of pulse signals or high frequency components to the frame signals with polarity inverting at predetermined intervals when the panel is activated at a white level or a black level. FIG. 9 is a schematic block diagram showing a preferred embodiment of the present invention and FIG. 10 is a waveform diagram showing various voltage signals in the circuit of FIG. 9. Data signals are typically intelligence signals introduced via a keyboard or TV picture signals and are supplied to a buffer I/O interface 26. Furthermore, keyboard strobe signals or external synchronizing signals such as TV horizontal synchronizing signals and vertical synchronizing signals are supplied to a control timing circuit 22 in association with the data signals. The control timing circuit 22 is also supplied with pulse signals of a relatively short pulse width τ from a pulse signal generator 21. The control timing circuit 22 brings this pulse into synchronism with the external synchronizing signals. The synchronized pulse signals are furnished to a line-sequential scanning circuit 23, an inverter 24, the buffer I/O interface 26, an inverter 27, a line memory and latch 28 and a gradation pulse generator 30. The line-sequential scanning circuit 23 typically includes a counter and a decoder, with the former counting the pulse signals and the latter decoding the count of the counter and helping generating scanning signals having sequentially shifted phases as seen from FIGS. 10(b) and 10(c). The scanning signals are fed to the inverter 24 which in turn inverts the polarity of the scanning signals at the predetermined interval T. The resultant scanning signals from the inverter 24 are supplied to, for example, the row electrodes of the liquid crystal display panel via a scanning driver 25.
The buffer I/O interface 26 adds pulses of a pulse width τ as shown in FIG. 10(a) to the data signals as well as bringing the data signals into synchronism with the pulse signals from the control timing circuit 22. The data signals with the pulse signals added thereto are then fed to the inverter 27 which in turn inverts the pulse signals added to the data signals at the predetermined interval T whenever counting a given number of the pulse signals, for example. The output of the inverter 27 is then supplied to the line memory and latch circuit 28 wherein it is temporarily stored and fetched immediately in response to the pulse signals from the control timing circuit 22. The fetched data signals are supplied to a gradation pulse selector 29 which is supplied with a plurality of gradation pulses from the gradation pulse generator 30. These gradation pulses are ones which are to be interposed within the interval T. To provide the black level, one of the gradation pulses is a pulse signal which is equal in its effective value to the threshold voltage level and typically assumes a logic "0" level for a limited period of time. In addition, to provide the white level, another one of the gradation pulses is a pulse signal which is equal in its effective value to the maximum voltage V p and typically assumes a logic "1" level for a limited period of time. The effective voltage values of the remaining gradation pulse signals are somewhere between the threshold voltage V th and the maximum voltage V p and assume either the logic "1" level or the logic "0" level for a limited period of time in order to provide a half tone display.
The gradation pulse selector 29 selects gradation pulses, depending on the data signals supplied from the line memory and latch circuit 28. In other words, the logic "0" level signal is selected for the limited period of time when to display the black level and the logic "1" level signal is selected when to display the white level. Moreover, corresponding gradation pulses are selected to provide a desired half tone display. Accordingly, in displaying the white level, the frame signal with the pulse signal having the logic "1" level during the first pulse width T and the interval τ is applied to the panel. Particularly, this frame signal is supplied to the column electrodes of the panel via a data side driver 31.
Since the plurality of the pulse signals are interposed within the frame signals even when displaying the white level, it is possible to minimize the low frequency components and make the effective voltage values substantially constant. As a result, the threshold level of the panel is made fixed to insure stable display. The waveform of FIG. 10(d) represents the voltages applied between the column electrodes and the row electrodes when the panel is in the enabled state (or the white level), the waveform shown in FIG. 10(e) represents the data signals when the panel is in the disabled state and the waveform of FIG. 10(f) represents the voltages applied between the column electrodes and the row electrodes of the panel when the panel is in the disabled state (or the black level).
The pulse width τ of the pulse signals to be added to the data signals is selected such that the pulse signals do not assume any intermediate level between the black level and the white level. For example, assuming that the pulse width of the scanning signals as shown in FIGS. 10(b) and 10(c) is selected in the order of 130 μsec, the pulse width of the pulse signals added to the data signals is to be in the order of 20 μsec.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications are intended to be included within the scope of the following claims.
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A display device includes a combined dynamic scattering mode and twisted nematic mode cell structure including at least one first display electrode oriented in a first direction and a plurality of second display electrodes in a second direction. The plurality of second display electrodes oriented are supplied with a plurality of scanning signals of sequentially shifted phases with polarity inverted at a predetermined interval of time, whereas the first electrode is supplied with frame signals indicative of information to be displayed and having polarity inverted at the predetermined interval. In order to minimize variations in the threshold level of the display device, a plurality of pulse signals having a pulse width shorter than the pulse width of said scanning signals are added to the frame signals.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part patent application of copending application Ser. No. 08/583,910 filed Jan. 11, 1996 now Pat. No. 5,687,493.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electric appliances and, more particularly, to a retaining member that provides multiple retaining functions.
2. Prior Art
U.S. Pat. No. 4,357,519 discloses an electric steam iron with a handle and a rear cover that pivotably captures an electric cord bushing. The conductors are retained with a strain relief and a bolt attached against the housing. U.S. Pat. No. 5,367,799 discloses a cord grommet pivotably attached to a rear cover at cradles. U.S. Pat. No. 4,651,453 discloses an iron having a resistor assembly attached to a housing.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention a retaining member for an electric iron is provided comprising three sections. A first section is for attachment to a housing of the iron. The first section has a strain relief section for contacting an electric cord. A second section extends from the first section and has a curved portion that forms part of a pivotable connection point of a general ball shaped end of a bushing for the electric cord into the housing. A third section extends from the first section for holding an electronic component between the third section and the housing.
In accordance with another embodiment of the present invention in an electric appliance having a housing, an electronic module, and an electric cord extending into the housing, the improvement comprises a one-piece retaining member connected to the housing. The retaining member has a cantilevered arm holding the electronic module against the housing and a section that holds a portion of the electric cord in a sandwiched position between the housing and the retaining member to function as a strain relief connection for the portion of the electric cord.
In accordance with another embodiment of the present invention in an electric appliance having a housing and an electric cord extending into the housing through an electric cord bushing pivotably connected to the housing, the improvement comprises a mounting member connected to the housing and forming a portion of an electric cord strain relief and a portion of the electric cord bushing mount. The mounting member comprises a first section that presses a portion of the electric cord against the housing to thereby stationarily connect the portion to the housing and a second section with a curved portion. The curved portion captures a ball shaped end of the bushing against the housing such that the bushing can pivot at the curved portion but is otherwise fixedly attached to the housing.
In accordance with another embodiment of the present invention in an electric appliance having a housing, an electronic module, and an electric cord extending into the housing through an electric cord bushing pivotably mounted to the housing, the improvement comprises a mounting member connected to the housing having a section that holds the electronic module in a stationary position against the housing and a curved portion that captures a ball shaped end of the electric cord bushing against the housing to thereby pivotably mount the bushing to the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
FIG. 1 is a perspective view of an electric steam iron incorporating features of the present invention;
FIG. 2 is a cross-sectional view of the iron shown in FIG. 1 taken along line 2--2;
FIG. 3 is a top, rear and side perspective view of the retaining member shown in FIG. 2;
FIG. 4 is a partial schematic cross-sectional view of the iron shown in FIG. 2 taken along line 4--4; and
FIG. 5 is a partial schematic cross-sectional view of the iron shown in FIG. 4 taken along line 5--5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 there is shown a perspective view of an electric steam iron 10 incorporating features of the present invention. Although the present invention will be described with reference to the single embodiment shown in the drawings, it should be understood that features of the present invention can be embodied in many alternative forms of alternate embodiments. In addition, any suitable size, shape, or type of elements or materials could be used.
The iron 10 generally comprises a soleplate 12, a housing 14 with a rear cover 16, a control knob 18, a steam button 19, a surge button 20, a reset button 22, an electric cord bushing 24 and an electric cord 26. However, features of the present invention could be incorporated into other types of irons and other types of electrical appliances. Referring also to FIG. 2, the rear cover 16 has the reset button 22 attached to it. The rear cover 16 houses an electronic module 28 and a retaining member 30. In the embodiment shown, the module 28 is an auto-OFF module that has circuitry adapted to automatically turn the iron 10 OFF after a predetermined period of time, such as one hour. The reset button 22 is adapted to be moved by a user to depress an actuator 32 of the module 28 to reset the module. However, in alternate embodiments, any suitable type of electronic module or circuitry could be used.
The retaining member 30, in the embodiment shown, is a onepiece plastic or polymer member that is attached to the rear cover 16 by a screw 35. However, in alternate embodiments, other types of fasteners or attachment means could be used. Referring also to FIG. 3, the retaining member 30 has a first middle section 36, a second top section 38 and a third bottom section 40. References to top and bottom are made for description purposes only. The first section 36 includes two lateral holes 42, locating ribs 44, a center hole 46, and strain relief rib 48. The second section 38 extends from the top of the first section 36 and includes two top cantilevered arms 50. The top arms 50 each have a stabilizing section 52. A curved section 54 extends between the two arms 50 and forms an upward and rearward facing seating surface 55. An open space or gap 56 is provided between the two top arms 50. The third section 40 extends at a compound angle (see angles A and B in FIGS. 2 and 4) from one side of the bottom of the first section 36. The third section 40 has an offset step 62 (see FIG. 4) at the first section 36.
Referring also to FIGS. 2 and 4, two screws 34 pass through the screw bosses 64 (only one of which is shown) of the rear cover 16. The locating ribs 44 help guide the retaining member 30 onto the bosses 64 such that the holes 42 are aligned with screw holes in the bosses 64. The handle 21 has two bosses 65 (only one of which is shown) with holes that are aligned with the holes 42. The screws 34 are screwed into the bosses 65 to thereby sandwich the middle section 36 between the two pairs of bosses 64, 65. The center hole 46 is provided to allow a fastener 35 (see FIG. 2) to attach the member 30 to the rear cover 16 before the rear cover 16 and handle 21 are attached to each other. However, this need not be provided. The rear end of the stabilizing sections 52 of the top arms 50 rest against the rear cover 16. The bottom section 40 captures or sandwiches the electronic module 28 between the bottom section 40 and the rear cover 16 to thereby physically attach the module 28 to the rear cover 16. In a preferred embodiment the bottom section 40 is deflectable and is spring loaded against the module 28. Ribs 17 of the cover 16 help to keep the module 28 stationarily locked in place.
Referring also to FIG. 5, the bushing 24 includes a center channel 66 and a general ball shaped end 68. The electric cord 26 passes through the center channel 66 into the housing 14. The rear cover 16 has ribs 80 which the ball shaped end 68 is placed against. The curved section 54 of the top section 38 is located opposite the ribs 80 to pivotably support the bottom of the ball shaped end 68, but which nonetheless allows an open area at the bottom of the bushing 24 for the electric cord 26 to exit the bushing. The top of the rear cover 16 and the top rear of the handle 21 have open areas to form a hole 82 (see FIG. 4). The hole 82 is smaller than the ball shaped end 68, but is large enough for the ball shaped end 68 to pivotably rotate in the hole 82. The ball shaped end 68 is thus rotatably captured between the rear cover 16 and handle 21 at the hole 82 and the ribs 80 and the curved section 54. In alternate embodiments, the hole 82 could be solely in the rear cover or the handle.
As seen in FIG. 2, when the electric cord 26 exits the bottom of the bushing 24, it can branch into two sections 26a, 26b on opposite sides of the center hole 46 and between the retaining member 30 and the rear cover 16. The retaining member 30 presses the cord section 26b against the cover 16. In addition, the strain relief rib 48 on the retaining member 30 is positioned to press the cord section 26a against the cover 16. This forms a fixed attachment of the cord section 26a to the rear cover 16 and, thus, forms a strain relief for the cord 26. The rib 48 is adapted to be snapped off of the retaining member 30 when the cord 26 is a 220 volt electrical cord. However, the rib 48 is retained for use with a thinner 110 volt electrical cord.
The retaining member 30, in cooperation with the rear cover 16, is able to provide three different retaining functions. It is able to retain the module 28 with the rear cover 16. It is able to pivotably retain the electric cord bushing 24 with the cover 16. It is able to provide strain relief retainment of the electric cord 26 with the rear cover 16. These three functions are provided by only three parts; the rear cover 16, the retaining member 30 and the screw 35. This reduces the number of parts in the iron that would otherwise be needed. The method of assembly merely comprises properly positioning the components and attaching the screw 35 to the rear cover 16. Alternatively, if the screw 35 is not used, the two screws 34 attach the member 30 to the rear cover and handle.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A steam iron having a soleplate, a housing, an electric cord extending into the housing through a bushing pivotably mounted to the housing, and a retaining member mounted to the housing. The retaining member has a first section with a snap-off rib that forms a strain relief with the housing for the electric cord. The retaining member also has a second section with a curved portion that forms part of the pivotable connection of the electric cord bushing to the housing. A third section of the retaining member is a cantilevered arm that holds an electronic module against the housing.
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This is a Continuation-in-Part of Ser. No. 08/353,093, filed Dec. 9, 1994 now U.S. Pat. No. 5,558,261.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to apparatus which attaches to automobiles for carrying bicycles, and more specifically to carriers which provide a high level of security.
2. Description of the Prior Art
Prior art bicycle carriers typically attach to a trunk lid or bumper and are typically vulnerable to theft, and this is particularly true for designs which are adjustable. Recently, a carrier has been marketed which attaches to a rear mounted spare tire by use of a strap attachment which is easily cut, rendering the carrier and bike susceptible to theft.
SUMMARY OF THE INVENTION
The present invention not only provides a secure attachment, but it also accommodates a variety of mounting dimensions and positions on vehicle bumpers and trunks.
The carriers of the present invention employ an adjustable member for securing the carriers between the lower edge of the trunk lid or rear door and the upper edge of the trunk lid or rear door, and a unique locking mechanism is employed to facilitate secure attachment. In an alternative embodiment, the adjustable member is flexible to accommodate the contour of the vehicle. Apparatus for supporting and stabilizing a bicycle protrudes rearwardly and also employs a similar locking mechanism to secure the bicycle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a carrier in accordance with the present invention installed on a rear mounted spare tire.
FIG. 2 is a perspective view of the carrier of FIG. 1.
FIG. 3 is a side view, partially cut away, of the carrier of FIG. 1.
FIG. 4 is a top view of the bicycle stabilizing device.
FIG. 5a depicts a typical mounting position for bicycles on the carrier of FIG. 1.
FIG. 5b depicts an alternative mounting position uniquely attainable with the carrier of FIG. 1.
FIGS. 6a-6d illustrate the locking mechanism for securing a bicycle to the carriers.
FIG. 7 is a side view of another embodiment of the invention showing the carrier mounted to the rear of a van type of vehicle.
FIG. 8 is a side view of another embodiment of the invention showing the carrier mounted to the trunk lid of a vehicle.
FIG. 9 is a perspective view of the carrier of FIG. 7.
FIG. 10 is a perspective view of the carrier of FIG. 8.
FIG. 11 is a perspective view of the adjustable locking mechanism employed with the carriers of FIGS. 7-10.
While the invention will be described in connection with a preferred embodiment, it will be understood that it is not the intent to limit the invention to that embodiment. On the contrary, it is the intent to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1 there is shown a bicycle carrier described in my co-pending application, Ser. No. 08/353,093 now U.S. Pat. No. 5,558,261, of which this is a continuation-in-part. That carrier is attached to a rear mounted spare tire 10 of an automobile. As shown most clearly in FIG. 2, upper hooks 12 protrude in spaced relation from a defined base section 17. The lower hook 14 (or hooks) protrudes from a piston-like slide member 18 constrained to move within a channel 20 defined on the base frame structure. At its upper end this slide member is attached to an adjustable locking lever 22.
The adjustable locking mechanism (depicted in detail in FIG. 3) employs a lever 22 pivotally attached to the base structure at pivot 24. A threaded bolt member 26 is pivotally attached to the slide member 18 at one end and attached to the lever 22 at its other end through a pivotally mounted retainer 25 which allows axial rotation. By use of a threaded nut 27 at the connection to the slide, axial rotation of the bolt 26 within the retainer and threaded nut causes it to lengthen/shorten the distance between the locking lever and the slide member. In this manner the distance between the upper and lower hooks is adjustable to adapt to any size tire (or other object) to which the carrier is attached.
Once the distance between the hooks is adjusted, the carrier is clamped to the tire. First, the cam lever is placed in the lower position 28, causing the lower hook to extend. Then the cam lever is raised to the upper position 29, retracting the lower hook, to thereby clamp the carrier onto the tire. With the locking lever in this upper position, holes 30a in the lever (FIG. 2) now line up with holes 30b in the base section to allow for the addition of a padlock. As a further anti-theft feature of this carrier, when the cam lever is placed in its upper position, the threaded bolt 26 lies within the narrow channel 20 and is inaccessible.
In the two embodiments shown in FIGS. 7-11, the secure adjustment mechanism is adapted to trunk lids and rear doors. This is accomplished in part by the use of a connecting structural member positioned to extend partially or completely between the upper and lower attachment points for the carrier. Turning now to the embodiment shown in FIGS. 8 and 10, a base frame structure 110a is mounted to the trunk lid 111 of a vehicle. A lower hook member 112a and an upper hook member 114a clamp the trunk lid therebetween. A flexible structural member 118a (with a protective shield 119) extends between the hook members and is secured to the upper hook member 114a by a means of an adjustable locking mechanism 120a described in detail below and depicted in detail in FIG. 11. In the preferred embodiment this flexible structural member may comprise a plastic encased thick steel cable or a flexible steel bar, which due to its flexibility may bend over vehicle contour or obstructions.
Alternatively, a base frame structure of the carrier may be mounted to the rear of a van style vehicle (see FIGS. 7 and 9). In this embodiment the carrier base frame structure 110b has affixed thereto a lower hook member 112b, and positioning spacers 122. A flexible structural member 118b extends from an adjustable locking member 120b to the upper hook member 114b attached to the upper door edge 130 (or rain gutter).
The connection of the flexible structural member to the base frame structure (FIG. 7) or to the upper hook member (FIG. 8) is accomplished by means of a secure adjustable locking mechanism 120 (depicted in FIG. 11). Particularly, the flexible member 118 attaches to the adjustable locking mechanism via attachment to a sliding piston member 132 (said means of attachment may be by weld, bolt, or other means well known in the art). This piston moves within the channel member 136 under control of the cam lever 138. This cam lever pivots on the pinned axis 140 to move between the released position shown in FIG. 11 and a latched position with the cam lever lying within the channel 136. When in this latched position the holes 140 in the cam lever align with the holes 142 in the channel member for receipt of a shackle of a padlock.
To provide adjustment for the length of the flexible structural member, a threaded connector 143 is provided between the piston 132 and the cam lever 138. This connector, in the form of a threaded bolt, is connected to freely rotate axially at its head 144 where it connects to a pivot 146 on the cam lever. At its other end, it connects to the sliding piston at a pivoting threaded nut 148. Rotation of the head 144 therefore causes the distance between the lever and piston to shorten or lengthen.
When the cam lever is unlatched as shown in FIG. 11, the bolt connector 143 is accessible and may be turned to effect adjustment. When the cam lever 138 is latched, pivoted downwardly and positioned within the channel, the bolt connector is inaccessible due to the close fit within the channel.
Once the appropriate carrier has been attached to the vehicle of choice, a bike is mounted onto the support 16. (In the preferred embodiments the carriers are adapted to hold two bikes, side by side.) The support 16 (shown in detail in FIGS. 6a-6d) comprises one or more saddles or troughs 31 of sufficient size and dimension to accept the frame tube of a bicycle. These troughs are positioned to span a pair of support arms 32 projecting rearwardly from the base frame structure.
Attachment of the bike to the support is accomplished with a locking mechanism as illustrated sequentially in FIGS. 6a-6d. With a bicycle frame tube 40 positioned on the saddle 31, a hook member 42 is brought up and over the bicycle frame tube (FIG. 6b) and then into engagement therewith (FIG. 6c). The lower extremity of this hook is attached to a locking lever 48 through a pivotally attached threaded adjustment nut 46. This locking lever 48 is pivotally attached to a depending channel member 44 of the saddle member 31. By use of the adjustment nut 46 the reach of the hook can be selected to allow the locking lever to achieve a locked position (FIG. 6d). With this locking lever in the locked position, holes 50a in the locking lever now line up with holes 50b in the depending channel member 44 to allow the addition of a padlock. When in the locked position, as shown in FIGS. 2 and 6d, the adjustment nut 46 is enveloped within the depending channel member for security, in the same manner as the mechanism for locking the carrier onto the vehicle.
Once the bicycle frame has been mounted into the support saddle 31, as described above, the stabilizers 15 (shown in detail in FIG. 4) are attached to the bicycle frame 51. These stabilizers are mounted to the carrier base frame structure through pivoting joints 52, 54 and 56 (or equivalent universal joint). Extending from this jointed attachment is a first stabilizer arm 60 which terminates in a first jaw 62. A second jaw 64 is integral with a second sliding arm 65 which extends parallel to the first arm and through a block 66 carried on the first arm. This second arm slidingly engages the first stabilizer arm at attachment 68 such that a spring 70 between that attachment and the block biases the jaws closed against the bicycle frame 51. A loop handle 74 allows one to pull the second jaw open for easy attachment to the bicycle frame.
From the foregoing description, it will be apparent that modifications can be made to the apparatus and method for using same without departing from the teachings of the present invention. Accordingly, the scope of the invention is only to be limited as necessitated by the accompanying claims.
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The carriers described herein employ an adjustable locking member to secure the carrier to the rear of a vehicle. A locking channel incorporates a cam lever used to adjust and lock the carrier and renders the mechanism inaccessible when locked. Apparatus for supporting and stabilizing a bicycle protrudes rearwardly from the base member.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to jar devices for use during downhole fishing operations and the like and more particularly, but not by way of limitation, it relates to a dual acting hydraulic jar device that can be actuated through coiled tubing by both lift-up and set-down of supporting string weight.
2. Description of the Prior Art
There have been various forms of prior art jar devices which are extremely effective in loosening stuck pipe by providing a hammer type impact at a desired downhole location. Prior jarring devices are commonly run in conjunction with overshots, spears, etc., to aid in loosening a fish object once it has been caught or secured. Such jarring devices generally utilize energy of compressed fluids to drive a free-moving piston or hammer against the top of the jar device, which fluid compression is obtained by surface movement of the drill pipe or tubing string. Thus, there are various types of hydraulic, mechanical and hydromechanical drilling jars as well as dual acting hydraulic jars that have been utilized in the past, and there is even an up-down jar device which employs both a mechanically operated unit to deliver the down jar and a hydraulically operated unit for delivering the up jar. To Applicants' knowledge there have not been any dual acting hydraulic coil tubing jars.
SUMMARY OF THE INVENTION
The present invention relates to an improved type of hydraulic up/down jar device for use with coiled tubing or conventional workover strings in fishing applications. The device is particularly useful in through-tubing fishing and drilling operations. The jar device consists of a kelly cylinder connected to an intermediate hydraulic cylinder having a cylindrical detent restriction centrally thereof, and which is further connected to a lower sub cylinder. An upper hammer sub is rigidly secured over the top of the kelly cylinder that defines a cylindrical channel through which a mandrel slides reciprocally, such mandrel having a shoulder or striker head on one end and an anvil sub secured on the lower end. The anvil sub is of a diameter that is reciprocal through the kelly cylinder, and the anvil sub carries an elongate actuator rod or plunger for extension down through the hydraulic cylinder and lower sub. Seals between the actuating plunger and the ends of the hydraulic cylinder define a cylindrical space of larger diameter on either side of the restrictor as the regulator plunger carries a piston and metering ring valve through the restrictor circumfery thereby to control hydraulic oil flow from one end of the hydraulic cylinder to the other. This oil flow is controlled in response to mandrel movement in upward or downward mode, from restricted travel to sudden release and jar generation, by impact of mandrel shoulder and anvil surfaces on the downstroke, and the lower anvil and hammer surfaces on the upstroke.
A similar type of device having no restrictor and having the metering ring replaced by seals may be connected in series with the jar device to function as an intensifier and shock absorber. Thus, for example, the lower sub of the intensifier device may be threadedly inserted in the upper end of the mandrel of the jar device and the combination can be utilized to deliver up/down jars to be imparted to the stuck object or fish. While the hydraulic cylinder of the jar device contains a selected volume of hydraulic fluid, the similar sealed chamber in the hydraulic cylinder of the intensifier device contains a full volume of suitably compressible fluid. The intensifier then enables additional energy storing capacity thereby enhancing the impact of the jar device as well as isolating the reverberation whenever a jar is imparted.
Therefore, it is an object of the present invention to provide a jar device that can be utilized in through-tubing fishing and drilling operations.
It is also an object of the invention to provide a jar device that may be utilized to impart sequential up and down impact blows to a stuck object in relatively rapid manner.
It is yet another object to provide a jar device for use in coiled tubing applications.
It is still further an object of the present invention to provide a device of similar structure that can be added in series with the jar device to function as an impact intensifier and isolator.
Finally, it is an object of the present invention to provide an up/down hydraulic jar device for use with coiled tubing that can be easily assembled and reliably employed in the field to impart repetitive freeing blows to downhole stuck objects.
Other objects and advantages of the invention will be evident from the following detailed description when read in conjunction with the accompanying drawings which illustrate the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A, 1B, 1C and 1D are sequential vertical sections of the jar device of the invention shown at the up jar positioning;
FIGS. 2A, 2B, 2C and 2D are sequential views in vertical section of the jar device in the lowermost or down jar position;
FIGS. 3A, 3B, 3C and 3D are sequential views in vertical section of the jar device nearing completion of an up jar stroke;
FIG. 4 is a top plan view of a metering ring constructed in accordance with the present invention;
FIG. 5 is a section taken along lines 5--5 of FIG. 4; and
FIG. 6 is a view in vertical section of an alternative form of hydraulic cylinder which converts the jar device to an intensifier unit.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1A to 1D, a jar device 10 consists essentially of an outer cylindrical member 12 having an inner reciprocal member 14 disposed therein for sliding movement. The outer cylindrical member 12 consists of an upper kelly cylinder 16, an intermediate hydraulic cylinder 18 and a lower sub 20. The inner reciprocal member 14 consists of an upper cylindrical piece formed as a mandrel 22 having an annular shoulder 24 with downward-facing annular striker surface 25 formed on the upper end of mandrel 22 and having threads 26 formed around the lower end.
An anvil sub 28 is formed with cylindrical outer surface 29 and an upper annular bore 30 having inner sidewall 32 with threads 34 formed therearound. The annular end surface 36 forms as an up jar striking surface, as will be further described below. The lower end of anvil sub 28 is formed with an axial bore 38 having internal threads 40. Threadedly secured upwardly within bore 38 is a threaded end 42 of an actuating plunger 44. The actuating plunger 44 extends down through the hydraulic cylinder 18 (FIG. 1C) into the lower sub 20 and includes an upper seal face 46 which defines a lesser diameter slide way 48 adjacent to threads 50 having a block nut 52 threadedly secured thereon. A lower plunger 54 extends below threads 50. An axial port 55 extends down through mandrel 22 and plunger 44, 54. A meter ring 56 forming a sliding valve is suitably retained on slideway 48. The diameter of meter ring 56 is a selected small amount less than the inside diameter of a restrictor 58 disposed generally in the center of hydraulic cylinder 18. The restrictor 58 is about two inches in length as it functions with the mandrel plunger 44, seal face 46 and meter ring 56 to actuate the jar device, as will be further described below.
Referring now to the cylindrical outer member, the kelly cylinder 16 includes upper internal threads 60 which receives threads 62 of lower cylindrical end 64 of a hammer sub 66. The hammer sub 66 is generally cylindrical defining an interior bore 68 through which the mandrel 22 is slidingly received. Seal spaces are provided at annular groove 70 below thread engagement and at annular groove 72 above the thread engagement, as the upper portion of hammer sub 66 terminates in an upward facing annular surface 74. The annular hammer surface 74 functions to strike the annular mandrel surface 25 in the downward mode to effect jar impact, as will be further described below.
The kelly cylinder 16 has a cylindrical inner surface 76 for receiving the anvil sub 28 slidably therein as anvil sub outer surface 29 and kelly inner surface 76 are sized for close sliding fit. The lower end of kelly cylinder 16 includes internal threads 78 separating annular interior seal spaces 80 and 82. The hydraulic cylinder 18 then secures threadedly into the lower end of kelly cylinder 16. The upper end of hydraulic cylinder 18 includes a uniform, anvil cylindrical wall 84 which is reciprocally slidable relative to the mandrel plunger 54 and includes a seal gland 86 and suitable seal 87 for sealing around actuator plunger 44. On the outer side, the upper end of hydraulic cylinder 18 includes threads 88 and annular groove 98 for receiving a suitable O-ring 99 of conventional type, and the upper end terminates in a collar 100 for sliding reception of plunger 44. The threads 88 of hydraulic cylinder 18 are placed in secure threaded engagement with threads 78 of kelly cylinder 16.
The lower or box end of hydraulic cylinder 18 includes interior threads 104 as well as an annular relief 106. The interior of hydraulic cylinder 18 provides a uniform diameter chamber for containing hydraulic fluid or selected oil with opposite ends 108 and 110 being divided into essentially equal volume spaces 122 and 124 by the central restrictor 58 of narrower diameter. The restrictor 58 functions during both the upstroke and downstroke of mandrel 22 to control fluid flow easing between metering ring 56 and restrictor 58. Thus, the diameter at restrictor 58 is 1.300 inches (plus or minus 0.005 inches) and the diameter of metering ring 56 is smaller by a predetermined dimension suitable for the particular jar device size and hydraulic fluid viscosity, as will be further described.
The lower sub 20 having pin threads 111 at the bottom defines a cylindrical inner channel 113 which receives overrun of actuator plunger 54. The upper end of lower sub 20 is then received in the lower box end of the hydraulic cylinder 18 with threads 114 securely engaged with the box end threads 104 of the hydraulic cylinder 18. An annular groove 116 provides seating for an O-ring 117 that seals the joint as lower sub 20 terminates at annular end wall 118 while also defining a seal gland 120 housing a suitable form of packing seal 121, a sliding seal disposed tightly around the lower plunger 54. Thus, when the mandrel and actuating plunger are properly placed through hydraulic cylinder 18, a selected hydraulic fluid one-half fills either the upper volume 122 or the lower volume 124, the ends of which are sealed by the respective upper and lower packing seals within seal glands 86 and 120, respectively. An O-ring backed up by carbon packing seal is used in present design; however, special seals for the purpose are available.
FIGS. 1A through 1D show sequentially the full length of the jar device 10 as it is placed in the jar up attitude with mandrel 22 drawn all the way to its upper limit relative to the hammer sub 66. The hammer sub 66 constitutes the unit which receives impact, downward impact between annular surfaces 25 and 74 (FIG. 1A) and upward impact between annular surfaces 36 and 64 (FIG. 1B).
The jar device 10 is supported for operation by connection to a suitable tubing connector or other sub device, e.g., the sub connector 126 having pin threads 128, as shown in FIG. 1A. The sub connector 126 may be affixed to any of continuous tubing, a form of tubing string, or other coacting equipment such as an intensifier and/or shock absorber, as will be further described below. The lower end of jar device 10, as shown in FIG. 1D, may be connected via pin end thread 111 to a tool 130 which serves in some manner to attach to the fish or stuck object that is the subject of operation. Thus, attachment 130 may align and secure any of various tools such as an overshot, a spears tool, tapered tap tool or other forms of specialty fishing tools.
In operating the jar device 10, the hydraulic cylinder 18 is first charged with hydraulic fluid 132 sufficient to fill about one-half of the total volume of upper chamber 122 and lower chamber 124. Actually, the amount of hydraulic fluid 132 employed is approximately eleven ounces by liquid measure, and the hydraulic fluid may range from thinner to thicker fluids depending upon the speed with which the operator desires the jar device 10 to function. The thinner fluids deliver the faster operation and vice-versa.
Once the jar device 10 is readied, the jar device may be run down tubing in contact with the stuck object and with mandrel 22 extended all the way upward relative to positioning in the hammer sub 66 as shown in FIG. 1A. Suitable coiled tubing string weight controlled at the surface is then placed upon the jar device 10 to commence compression and down jar operation, for example 5000 lbs. and up. As shown in FIG. 1C, there is no initial resistance to downward movement of plunger 44 and meter ring 56 until the block nut 52 enters the restrictor 58 and comes into contact with the hydraulic fluid 132. The outside diameter of block nut 52 has narrow clearance relative to restrictor 58 and the slidable meter ring 56 has a clearance of 0.001 inches relative to the inside diameter of restrictor 58 so that even under great weight, the meter ring 56 progresses relatively slowly down through restrictor 58 until it passes the bore point 134 (FIG. 1C) where it then allows relatively free escape of the hydraulic fluid 132 from the lower chamber 124 upward around meter ring 56 and seal plate 46 and, at the same time, allows accelerated downward movement of plunger 44. At the limit of downward fall, the annular mandrel surface 25 impacts with annular hammer surface 74 (FIG. 1A) to provide a down jar to the stuck object as held by sub unit 130.
Under the very great pressures present in the upper chamber 122 and lower chamber 124 during operation, i.e., fluid pressures on the order of 16-17,000 psi and up, the sidewalls of hydraulic cylinder 18 tend to experience a slight stress enlargement. In order to compensate for such high pressure stress enlargement, the meter ring 56 includes a plurality of upper relief holes 136 and lower relief holes 138 which are each drilled halfway through the vertical dimension of meter ring 56 and serve to impart an enlarging effect as higher pressure fluid is applied. As shown in FIGS. 4 and 5, the meter ring 56 includes a plurality of equi-spaced vertical holes 136, on the order of six to eight holes, drilled from the top halfway down through the vertical dimension of meter ring 56. Alternatively, for pressure equalization during opposite direction movement, a similar plurality of equi-spaced holes 138 are formed in offset from the bottom of meter ring 56 to a point halfway along the height. The holes 136 and 138 are each formed with a diameter of 0.030 inches in present design.
Referring to FIGS. 2A through 2D, the jar device 10 is in the attitude just following a down jar wherein mandrel annular surface 25 has impacted on annular hammer surface 74 as shown in FIG. 2A. At this point, the mandrel 22 is at its lowest extremity positioning anvil 28 downward adjacent collar 100 of hydraulic cylinder 18, and the seal face 46 and meter ring 56 are disposed in the lower chamber 124 of hydraulic cylinder 18, well below the level of hydraulic fluid 132 which is raised up to about the upper bore point 133 of restrictor 58. In like manner, the lower plunger 54 is positioned all the way down within lower sub 20 and adjacent the lower sub connector 130.
The up jar is commenced by applying lift up force on the coiled tubing string which has the effect of drawing mandrel 22 upward thereby to commence the up jar sequence. As the mandrel 22 is drawn upward, the plunger 44 is drawn steadily upward to bring the seal face 46 and meter ring 56 up across lower bore point 134 into restrictor 58. This brings the seal plate 46 up into restrictor 58 with minimal fluid restriction until the close fitting meter ring 56 passes the lower bore point 134 to carry the hydraulic fluid 132 trapped thereabove upward until compression of remaining air and hydraulic fluid above the meter ring 56 whereupon the meter ring 56 slowly leaks hydraulic fluid around its circumfery. The circumference of meter ring 56 has about 0.001 inches clearance relative to the side wall of restrictor 58 and, in response to the extreme pressures within hydraulic cylinder 18, the upper holes 136 around meter ring 56 will expand under fluid pressure to maintain the clearance constant relative to the slightly expanding inner diameter of restrictor 58.
FIGS. 3A through 3D show the attitude of jar device 10 at a point in upward traverse of mandrel 22 where the hydraulic fluid 132 can enjoy free flow of fluid around the meter ring 56 and components, and the full upward force can act to raise the plunger 44 (FIG. 3B) to force the anvil 28 rapidly upward thereby to impact the annular anvil surface 36 against the annular hammer surface 64 to effect the up jar.
After the up jar, the jar device 10 is once again in the attitude depicted in FIGS. 1A through 1D and ready for commencement of a down jar sequence. Thus, by periodically shifting the applied weight and liftup to the coiled tubing, as controlled from the surface, the jar device 10 can be sequenced through repeated up and down jars of the fish until it is freed for movement by the sub attachment 130.
The jar device 10 has the capability of being altered to what is termed an intensifier by changing out a single component. Thus, when the detent cylinder 18 of jar device 10 is substituted with a hydraulic cylinder 140, as shown in FIG. 6, the device becomes an intensifier capable of intensifying or accelerating the impact of jar device 10 while also serving as a shock absorber as regards vibrations attempting to travel thereacross. The alterations are essentially directed to elimination of the restrictor 58, replacement of the metering ring 56 with a plurality of slidable seals, and replacement of the hydraulic fluid 132 with a full chamber of a selected compressible fluid, as will be further described.
The intensifier 140 is still interconnected between kelly cylinder 16 and a lower sub 20 as intensifier 140 still retains the similar end connector components as the hydraulic cylinder 18. Thus, the upper end of intensifier cylinder 140 still has an upper collar 142 and axial bore 144 with outer threads formed for engagement with kelly interior threads 78. See FIG. 1C. An annular seal gland 148 provides seating for a tube seal 150 while an upper annular groove provides seating for a standard type of O-ring (FIG. 1C).
The axial bore 144 leads downward into a generally cylindrical elongate chamber 156 which is defined by the outer wall 158 having an inner surface 160. The chamber 156 terminates at the bottom at annular collar 118, the end wall of lower sub 20, as it is engaged with lower internal threads of intensifier cylinder 140. The packing seal 121 and O-ring remain functional as in the previous embodiment of jar device 10.
The same type of upper plunger 44, seal face 46, threads 50, block nut 52 and lower plunger 54 are employed in the FIG. 6 intensifier embodiment. The difference here is the employment of a seal assembly 162, four cup-shaped seals 164, 166, 168 and 170, which is compressed between seal face 46 and block nut 52. Each of the seals 164-170 are identical except that they are positioned in two by two relationship with the upper two seals 164 and 166 aligned with cup up and the lower two seals 168 and 170 aligned with cup down. The seals 164-170 are made of TEFLON® and specially constructed by Johns Manville to provide a tight seal withstanding up to 20,000 psi. In assembly, the seals are subjected to 0.013 inches squeeze suppression by adjustment of block nut 52. A compressible liquid 172, a selected Dow-Corning silicon fluid type completely fills the chamber 156.
In operation, an intensifier unit is assembled consisting of a hammer sub 66, connected to a kelly cylinder 16 (FIGS. 1A and 1B) which is then connected to an intensifier hydraulic cylinder 140 (as in FIG. 6) with attachment of lower sub 20. The interior moving element would consist of the mandrel 22 connected to the anvil 28 which extends the plunger 44-54 down through the axial kelly cylinder 16 and accelerator chamber 156 within hydraulic cylinder 140. Within chamber 156, the plunger 44 would include the seal face 46, plural opposed cup-shaped seals 164-170 and the block nut 52 securing the seal assembly 162. A complete charge of compressible oil of selected type is placed within chamber 156. With the seal assembly 162 positioned near the top of chamber 156, the intensifier unit could be utilized for down jar only. With seal assembly 162 in the middle of chamber 156, the intensifier unit is usable for both up and down jar operation, and when the seal assembly 162 is at the bottom of chamber 156 it is suitable for use in up jar applications. The initial positioning of the mandrel 22 may be attended by the operator on commencement of operation when oil filling takes place.
The intensifier unit may be placed directly in connection with the jar device 10 by threadedly interconnecting the coupling units. That is, the pin end threads 110 of a lower sub 20 of the intensifier unit could be connected directly into the box threads 23 of mandrel 24 on the jar device 10. In some cases, however, there may be other intervening sub units included between the intensifier unit and a jar device 10. Also, in cases where only the shock absorption feature is to be availed of, the properly assembled intensifier unit may be used separate and apart from the jar device 10.
The intensifier unit serves to intensify acceleration of the jarring member during both up and down jar impacts, while also functioning as a shock absorber as regards any impact vibration that attempts to travel up the tool string from the work point, i.e., the point where the object or fish is receiving jars. Thus, as weight bears down upon the intensifier plunger 44 and the plural cup-shaped seals 164-170, increasing pressure and therefore energy is stored within the volume of compressible fluid 172 therebeneath. When the jar device 10 completes its bleed-down phase, that is (referring to FIG. 1C) when the meter ring 56 has cleared the restrictor 58 and descends below bore point 134, the plunger 44-54 accelerates rapidly to impact causing the requisite jar. Also, this acceleration is greatly aided by the acceleration energy that is stored in the compressible fluid within the hydraulic cylinder 140 of the intensifier unit. This same jar intensity augmentation is realized whether the combination operates in up jar, down jar or up-down jar modes.
While providing the intensifying function by means of the pressure seal assembly 162 as retained on slideway 48, the structure also has the capability of absorbing any shock transmitted along or through hydraulic cylinder 140 as such vibrational energy is dissipated within the compressible fluid 172. In order to achieve purely shock absorption effectiveness, it is best that the hydraulic cylinder 140 be loaded initially at the center position of chamber 156 with ample room for movement in either direction.
The foregoing discloses a novel downhole tool that may be used with coiled tubing as an up/down jar device capable of delivering repeated up and down blows to a stuck object at a relatively rapid rate of repetition. In addition, the jar device exhibits great versatility both in implementation as a jar generator and for other functions which are enabled by merely offering the characteristics of a central hydraulic cylinder and piston assembly. In the one case, a two-way hydraulic cylinder with a central restrictor is utilized for function in the up or down jar mode of operation while a quick change-over of the hydraulic cylinder, to one of a cylinder without restriction and a high pressure seal type of piston, enables operation as an impact intensifier or accelerator as well as a shock absorber for isolating impact disturbance.
Changes may be made in the combination and arrangement of elements as heretofore set forth in the specification and shown in the drawings; it being understood that changes may be made in the embodiments disclosed without departing from the spirit and scope of the invention as defined in the following claims.
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A hydraulic jar device for use in through-tubing drilling and fishing operations which consists of an elongate tube having an upper hammer sub, a kelly cylinder and a hydraulic cylinder with central restrictor secured therebelow. A lower sub connects to the bottom end of the hydraulic cylinder. The sliding interior components are an upper mandrel secured to an anvil sub which, in turn, is fastened to an axial plunger, all of which are slidable down within the elongate tube. A metering ring retained on the plunger interacts with the central restrictor of the hydraulic cylinder to control force effected up and down jars that occur when the mandrel strikes the hammer sub on the down stroke, and when the anvil sub strikes the hammer sub bottom on the up stroke.
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[0001] This application claims the benefit of Korean Application No. P2003-079414, filed on Nov. 11, 2003, and No. P2003-089508, filed on Dec. 10, 2003, which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a dryer accessory, and more particularly, to a dryer rack used in a dryer or washing machine equipped with a drying function.
[0004] 2. Discussion of the Related Art
[0005] Generally, a dryer or washing machine equipped with a drying function is an apparatus for drying objects such as a laundry and the like held in a drum by supplying hot air to the drum. And, a demand for such an apparatus is gradually raised lately.
[0006] A lifter is provided within the dryer or washing machine to enhance drying performance in general. The lifter and drum are individually manufactured, and the lifter is then installed on an inside of the drum via a locking member such as a screw and the like. Instead, a lifter can be proved by ‘pressing’ in a manner that a circumferential surface of a drum is pressed to protrude from an inside of the drum. In drying an object to be dried, the corresponding object held within a drum is lifted by a plurality of lifter protruding inward from an inside of a drum up to a predetermined height and then falls. The object is easily exposed to hot air supplied to the drum to be evenly dried, thereby enhancing drying efficiency. Thus, if using the dryer or washing machine equipped with the drying function, such a relatively light drying object as cloths and the like can be conveniently dried.
[0007] However, it is difficult to dry a relatively heavy drying object using a general dryer or washing machine equipped with the drying function. Since the heavy drying object lifted by the lifters gives a considerable shock to the drum when falling, loud noise is generated from the drum or the corresponding dryer or washing machine may be out of order.
SUMMARY OF THE INVENTION
[0008] Accordingly, the present invention is directed to a dryer rack that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0009] An object of the present invention, which as been devised to solve the foregoing problem, lies in providing a dryer rack, by which a relatively heavy drying object can be easily and safely dried.
[0010] Another object of the present invention is to provide a dryer rack, which can be easily attached to a drum of a dryer/washer to use.
[0011] A further object of the present invention is to provide a dryer rack, which can be stably and firmly loaded in a drum of a dryer/washer to use.
[0012] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent to those having ordinary skill in the art upon examination of the following or may be learned from a practice of the invention. The objectives and other advantages of the invention will be realized and attained by the subject matter particularly pointed out in the specification and claims hereof as well as in the appended drawings.
[0013] To achieve these objects and other advantages in accordance with the present invention, as embodied and broadly described herein, there is provided a dryer rack for use with an apparatus for drying an object inside a drum, wherein the dryer rack includes a platform having an upper surface for supporting the object. The platform may include at least one grip for loading and unloading the dryer rack into a interior space of the drum. The at least one grip is flush with the upper surface of the platform. The at least one grip is formed in a forward portion of the platform, to be near an access point of the drum.
[0014] The at least one grip may include an opposing pair of openings formed in the platform, and a gripping surface formed on inner side surfaces on each opening. The gripping surface may be textured to facilitate gripping. And, the gripping surface may include a set of curved recesses corresponding to digits of a human hand. The gripping surfaces of the opposing pair of openings may be symmetrically arranged with respect to a centrally disposed handle.
[0015] The gripping surfaces of the opposing pair of openings are asymmetrically arranged with respect to a centrally disposed handle. Herein, the asymmetrical arrangement of the gripping surfaces provides for a thumb and four fingers, respectfully. The platform may include a pair of grips, symmetrically arranged about a central axis of the platform, for loading and unloading the dryer rack into an interior space of the drum. The pair of grips may be flushed with the upper surface of the platform. The pair of grips may also be formed in a forward portion of the platform, to be near an access point of the drum. And, the grips may be arranged at opposing angles for facilitating a two-handed grip when loading and unloading the dryer rack. Herein, the opposing angles may be between 10° and 20°.
[0016] The platform may include a tray, forming the upper surface between a forward end and a rearward end of the tray, a front support, connected to the forward end of the tray, to be supported by a first structure, and a rear support, connected to the rearward end of the tray, to be supported by a second structure, wherein the first and second structures respectively provide rotatable support to opposite ends of the drum. Herein, the plat form may include at least one grip for loading and unloading the dryer rack into an interior space of the drum. And, the at least grip may be flushed with the upper surface of the platform.
[0017] The front and rear supports may have lower surfaces for seating the dryer rack on the first and second structures. Herein, the lower surfaces of front and rear supports may be shaped to avoid interference with the drum if the drum is rotated while the dryer rack is loaded into an interior space of the drum. The platform may have a lattice structure.
[0018] In another aspect of the present invention, there if provided a dryer rack for use with an apparatus for drying an object inside a drum, wherein the dryer rack includes a tray having an upper surface for supporting the object between a forward end and a rearward end of the tray, a front support, connected to the forward end of the tray, having a first lower surface for receiving a first structure, and a rear support, connected to the rearward end of the tray, having a second lower surface for receiving a second structure, wherein the first and second structures respectively provide rotatable support to opposite ends of the drum.
[0019] The front support may rest atop a filter, installed forward of the drum, for filtering air expelled from the drum. The front support may include a pair of side extensions, connected to the forward end of the tray, for supporting the dryer rack on the filter, and an arch, stretching between the side extensions and extending downward, for being seated on an upper surface of the filter having a centrally formed recess, the arch having an arch projection for insertion into the recess of the filter.
[0020] The side extensions may be disposed forward of the tray. The rear support may include at least one leg, connected to the rearward end of the tray, for supporting the dryer rack on the second structure. The second structure may be a semicircle. Herein, the at least one leg has a curved lower surface for being seated on the semicircle of the second structure. And, the rear support may include at least two legs, connected to the rearward end of the tray, for supporting the dryer rack on the second structure, the at least two legs having opposingly curved surfaces for being respectively seated on a semicircle of the second structure.
[0021] The dryer rack may include at least one grip, formed in the upper surface of the tray, for loading and unloading the dryer rack into an interior space of the drum. The at least one grip may include an opposing pair of openings formed in the platform, and a gripping surface formed on inner sides surfaces on each opening. Herein, the griping surface may be textured to facilitate gripping. The gripping surface may include a set of curved recesses corresponding to digits of a human hand. The gripping surfaces of the opposing pair of openings may be symmetrically arranged with respect to a centrally disposed handle. Also, the gripping surfaces of the opposing pair of openings may be asymmetrically arranged with respect to a centrally disposed handle. The asymmetrical arrangement of the gripping surfaces provides for a thumb and four fingers, respectively.
[0022] In a further aspect of the present invention, there is provided a dryer rack for use with an apparatus for drying an object inside a drum, wherein the dryer rack includes a platform having an upper surface for supporting the object between a forward end and a rearward end of the tray, the upper surface having a lattice structure, a front support, connected to the forward end of the platform, having a first lower surface for receiving a first structure providing rotatable support to the drum, and at least one leg, connected to the rearward end of the platform, having a second lower structure for receiving a second structure providing rotatable support to the drum, and at least one handle provided with an opposing pair of openings formed in the platform, each opening having a gripping surface formed on an inner side surface, wherein the at least one handle is flush with the upper surface of the platform.
[0023] It is to be understood that both the foregoing explanation and the following detailed description of the present invention are exemplary and illustrative and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention and together with the description serve to explain the principle of the invention. In the drawings:
[0025] FIG. 1 is a cross-sectional diagram of an exhaust type dryer;
[0026] FIG. 2 is a perspective diagram of a dryer rack according to one embodiment of the present invention;
[0027] FIG. 3 is a perspective diagram of a dryer rack according to another embodiment of the present invention;
[0028] FIG. 4 is a perspective diagram of a front part of a dryer rack provided to a dryer according to the present invention; and
[0029] FIG. 5 is a perspective diagram of a rear part of a dryer rack provided to a dryer according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Throughout the drawings, like elements are indicated using the same or similar reference designations where possible.
[0031] First of all, a dryer rack according to the present invention can be installed in an exhaust type dryer, condensing type dryer, washer/dryer, or the like to use. In the exhaust type dryer, external air is heated to be supplied to a drum and humid air having dried a drying object within the drum is discharged outside. In the condensing type dryer, air, which is humid after having dried a drying object within a drum, is condensed by a condenser to lower humidity thereof and is then heated to be re-supplied to the drum. For convenience of explanation, a dryer rack according to the present invention installed in the exhaust type dryer is explained in the following description for example.
[0032] Referring to FIG. 1 , a drum 20 is rotatably provided within a cabinet 10 of a dryer. The drum 20 has a cylindrical shape, and a plurality of lifters 25 protrude from an inside of the drum 20 . The lifter 25 and the drum 20 are separately manufactured. Hence, the lifter 25 is attached to the inside of the drum 20 later. Instead, the lifters 25 may be built in one body of the drum 20 . A front panel 21 and rear panel 23 are mounted on an open front side and open rear side of the drum 20 to rotatably support, respectively so that the drum 20 supported by the front and rear panels 21 and 23 can be rotated in operating the dryer. While the dryer is operated, the drum is rotated but the front and rear panels 21 and 23 are not rotated.
[0033] An opening 21 a is provided to the front panel 21 , and a door 15 is installed on the front side of the cabinet 10 to open/close the opening 21 a . An exhaust duct 30 is connected to the front panel 21 . Hence, an inside of the drum 20 , as shown in FIG. 1 , enables to communicate with an external environment outside the cabinet 10 via the exhaust due 30 . Within the exhaust duct 30 , a fan 40 blowing air in the drum 20 outside and a filter 35 filtering the air discharged outside by the fan 40 are provided. The fan 40 , as shown in FIG. 1 , is rotated by a motor 50 provided within the cabinet 10 .
[0034] Meanwhile, the motor 50 may be provided to rotate the fan 40 only. Yet, in the drawing, the motor 50 is provided to rotate both of the fan 40 and the drum 20 . For this, the motor 50 includes a pair of shafts connected to the fan 40 and a pulley 60 , respectively. And, the pulley 60 , is connected to the drum 20 via a belt 65 . An air inlet duct 70 is connected to the rear panel 23 to enable the inside of the drum 20 to communicate with an external environment. As the fan 40 rotates to discharge the air within the drum 20 outside via the exhaust duct 30 , external air is supplied into the drum 20 via the air inlet duct 70 . Meanwhile, a heater 80 , as shown in FIG. 1 , is installed in the air inlet duct 70 to supply hot air into the drum 20 .
[0035] Meanwhile, a dryer rack 100 according to the present invention is detachable installed in the drum 20 of the above-constructed dryer. The dryer rack 100 can be conveniently used in drying relatively heavy objects. The dryer rack 100 according to the present invention is explained in detail by referring to FIG. 2 and FIG. 3 as follows.
[0036] Referring to FIG. 2 and FIG. 3 , a platform is provided to the dryer rack 100 to be detachably loaded in the drum 20 and to support a drying object thereon. A tray 110 having the drying object put thereon, a front support 120 extending from a front side of the tray 110 , and a rear support 130 extending from a rear side of the tray 110 are provided to the body. The tray 110 may be constructed with a perforated panel so that air can pass through the platform or have lattice shape shown in FIG. 2 . Hence, hot air supplied into the drum 20 can be smoothly provided to the drying object put on the tray 110 , whereby drying efficiency is enhanced.
[0037] The front support 120 is supported by a structure fixed to an inner front side of the dryer or washer such as the front panel 21 . And, the rear support 130 is supported by a structure fixed to an inner rear side of the dryer or washer such as the rear panel 23 . Hence, when the dryer rack 100 is loaded in the drum 20 , the tray 110 enables to maintain its position by the front and rear supports 120 and 130 without rotating within the drum 20 . In loading the dryer rack 100 in or unloading out of the drum 20 , the body, e.g., right and left sides of the tray 110 , should be taken. Hence, the loading and unloading works are inconveniently performed.
[0038] Moreover, a size of the body, and more particularly, a right-to-left width of the tray 110 , should be much smaller than a diameter of the opening 21 a . If the right-to-left width of the tray 110 is too long, it is inconvenient for a user to install or uninstall the dryer rack 100 . Besides, the user may be hurt by the opening 21 a . Hence, at least one grip 150 is provided to the dryer rack 100 according to the present invention to overcome such a problem. The at least one grip 150 is provided to the body, and more particularly, to the tray 110 so that a user can conveniently hold it to load/unload the dryer rack 100 in/from the drum 20 . The grip 150 is explained in detail by referring to FIG. 2 and FIG. 3 as follows.
[0039] Referring to FIG. 2 and FIG. 3 , the at least one grip 150 if formed at the body, and more particularly, on such a plane as the tray 110 . And, the at least one grip 150 includes a plurality of openings 151 and a grip 155 . Specifically, a pair of openings 151 , as shown in FIG. 2 and FIG. 3 , are provided to the body, and more particularly, to the tray 110 to neighbor each other. And, the grip 155 lies on a boundary of the two neighboring openings 151 to be built in one body of the tray 110 . Thus, if the grip 150 is provided to the tray 110 , a user inserts his fingers in the openings 151 to grab the corresponding grip 155 . The user then lifts the dryer rack 100 to install/uninstall in/from the drum 20 .
[0040] Meanwhile, the grip 155 preferably includes a structure enabling user's fingers to closely adhere thereto. For this, outsides of the grip 155 are formed uneven or a multitude recesses 155 a are formed on both lateral outsides of the grip 155 . A pair of the openings 151 having user's fingers inserted therein may be symmetric or identical to each other in shape. Yet, the present invention does not put limitation of the shapes of the openings 151 that can be variously modified. For instance, when a user grabs the corresponding grip 155 , user's thumb is inserted in one of the two neighbor openings 151 and the rest user's fingers are inserted in the other opening 151 . Hence, a pair of the neighbor openings 151 can be differently shaped to be fit for the thumb and the reset fingers of the user, respectfully.
[0041] Meanwhile, in order to facilitate to install the dryer rack 100 in the drum 20 , the grip 150 , as shown in FIG. 2 and FIG. 3 , is provided to a front part of the body, and more particularly, of the tray 110 . Moreover, in order to facilitate a user to grab the grip 150 using both hands, a pair of the grips 155 are symmetrically provided to the front part of the tray 110 . Furthermore, in order to facilitate a user to grab the grip 150 conveniently, the grip 155 , as shown in FIG. 2 , is tilted against a central axis in a length direction of the body, and more particularly, of the tray 110 . In this case, the grip 155 , as shown in FIG. 2 , is tilted in a manner of extending from its rear part to its front part to get farther from the central axis. And, the corresponding tilted angle is about 10°˜20°, and more preferably, about 15°.
[0042] Once the above-constructed grip is provided to the dryer rack 100 , a user grabs the grip(s) 155 of the grip(s) 150 to load the dryer rack 100 in the drum 20 with ease. When the dryer rack 100 is loaded in the drum 20 , the front and rear supports 120 and 130 are supported by immovable structures within the cabinet 10 . Yet, in a drying operation, the drum 20 keeps rotating to generate vibration. Hence, the dryer rack 100 may fall down if failing to be securely loaded therein. Hence, the front and rear supports 120 and 130 include the structures for stable loading, respectively, which are explained in detail by referring to FIGS. 2 to 5 as follows.
[0043] First of all, the front support 120 can closely adhere to the front panel 21 in direct to be supported or to a topside of the filter 35 in FIG. 1 provided to the front side of the drum 20 for filter air discharged from the drum 20 . Generally installed on the front panel 21 , the filter 35 can be regarded as a part of the front panel 21 . A curved portion 123 , a projected portion 121 , and a pair of end portions 125 are provided to the front support 120 . For example, the curved portion 123 , as shown in FIG. 2 and FIG. 3 , is convex downward. And, the curved portion 123 , as shown in FIG. 4 , closely adheres to the topside of the filter 35 . And, the projected portion 121 , as shown in FIG. 2 and FIG. 3 , is projected downward from a middle part of the curved portion 123 . The projected portion 121 , as shown in FIG. 4 , is fitted in a recess 35 a formed in the middle of the filter 35 .
[0044] Moreover, a pair of the end portions 125 , as shown in FIG. 2 and FIG. 3 , are provided to both side ends of the curved portion 123 . And, a pair of the end portions 125 , as shown in FIG. 4 , closely adhere to both ends of the topside of the filter 35 to be supported thereon, respectively. The end portions 125 , as shown in FIGS. 2 to 4 , protrude in a front direction. Meanwhile, the rear support 130 closely adheres to an inner circumference 23 a of the rear panel 23 rotatably supporting the rear side of the drum 20 to be supported thereon. A pair of legs 131 , as shown in FIG. 2 , FIG. 3 , and FIG. 5 , protruding from the body, and more particularly, from both corners of a rear side of the tray 110 are provided to the rear support 130 .
[0045] A pair of the legs 131 , as shown in FIG. 5 , are contacted with the inner circumference 23 a of the rear panel 23 to closely adhere thereto. For this, a curved portion 131 a having the same curvature of the inner circumference 23 a of the rear panel 23 is provided to each lower part of the legs 131 . As mentioned in the foregoing description of the present invention, the front support 120 closely adheres to a portion of the front panel 21 , and more particularly, to the filter 35 to be supported thereon, and the rear support 130 closely adheres to the inner circumference 23 a of the rear panel 23 to be supported thereon. Therefore, the dryer rack 100 installed in the drum 20 according to the present invention enables to maintain a stable loaded state even if vibration is generated from the drying operation.
[0046] A process of drying an object to be dried using the above-constructed dryer rack 100 according to the present invention is explained as follows. First of all, a user grabbing the grip 15 carries to load the dryer rack 100 in the drum 20 . In doing so, user's hands are not exposed in both right and left directions of the dryer rack 100 . Hence, the user enables to insert the dryer rack 100 in the drum 20 via the opening 21 a conveniently even if the dryer rack 100 has a full-sized right-to-left width. Besides, since the grips 150 are provided to the front part of the dryer rack 10 , the user just lays his hands on the grips 150 in the vicinity of the opening 21 a conveniently. Once the dryer rack 100 is loaded in the drum 20 , the user makes the rear support 130 closely adhere to the inner circumference 23 a of the rear panel 23 to be supported thereon and also makes the front support 120 closely adhere to the portion of the front panel 21 , e.g., the filter 35 , to be supported thereon. After completion of loading the dryer rack 100 in the drum 20 , a drying object is placed on the tray 110 , the door is closed 15 , and the dryer is then actuated.
[0047] Once the dryer is actuated, the drum 20 and fan 40 start to rotate as well as the heater 80 it turned on. Air within the drum 20 is then discharged outside via the exhaust duct 30 as well as hot air is supplied to the drum 20 via the air inlet duct 70 . The hot air supplied to the drum 20 dries the drying object placed on the tray 110 of the dryer rack 100 . In doing so, as the hot air passes through the tray 110 upward and downward, it is able to dry the drying object evenly. Besides, as the drying object stays onto the tray 110 of the dryer rack 100 during the drying process, noise and shock fail to occur within the drum 20 .
[0048] The air, which becomes humid air after drying the drying object within the drum 20 , is then discharged outside via the exhaust duct 30 . In doing so, particles contained in the humid air are removed by the filter 35 so that clean air can be discharged outside only. Accordingly, the dryer rack according to the present invention facilitates to dry the relatively heavy drying object. It is a matter of course that the noise and shock caused by the fall of the drying object do not occur within the drum while the drying object is dried using the dryer rack. Therefore, the present invention enables to prevent the drum from being broken down and to secure the endurance of the drum.
[0049] And, the grips are provided to the dryer rack according to the present invention, thereby facilitating a user to load/unload the dryer rack in/from the drum. Moreover, the grips are tilted, thereby facilitating the user to grab the corresponding grips conveniently. Besides, there is a sufficient margin for designing the right-to-left width of the dryer rack, whereby a large amount of the drying object can be handled at the same time by the dryer. Furthermore, the dryer rack can be loaded/unloaded in/from the drum without danger of injury using the grips.
[0050] Moreover, the front and rear supports are provided to the front and rear sides of the dryer rack according to the present invention, respectively and are constructed to closely adhere to the structures supporting them. Therefore, even if vibration is generated from the drying operation, the dryer rack loaded in the drum does not move or rock side to side so that the drying object can be safely dried.
[0051] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover such modifications and variations, provided they come within the scope of the appended claims and their equivalents.
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A dryer rack for use with an apparatus for drying an object inside a drum is disclosed, wherein the dryer rack includes a platform for having an upper surface for supporting the object. The platform may include at least one grip for loading and unloading the dryer rack into an interior space of the drum. The at least one grip is flush with the upper surface of the platform. The at least one grip is formed in a forward portion of the platform, to be near an access point of the drum.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a washing process for institutional laundries in which different detergents are introduced into the liquor in the same wash cycle, but at different stages of the washing process.
2. Discussion of Related Art
In institutional laundries, different detergents are often introduced into the liquor in the same wash cycle, but at different stages of the washing process, for example first a detergent containing anionic surfactants and later a detergent containing nonionic surfactants. In recent years, washing processes have been continually improved both from the ecological and from the economic point of view. Reductions have been achieved in the use of energy, detergent, water and time. Significant improvements in this regard were obtained in particular by introduction of the countercurrent washing principle and fully continuous or cycle-dependent batch washing machines. However, further savings of detergent, water, particularly rinsing water, energy and time have been prevented by the absence of reliable, continuous and automatic processes for determining the concentration of detergents and bleaches in the liquor. The measuring signal of such processes could be used to control metering, to terminate individual process steps, etc., so that a satisfactory washing result could be obtained with the minimum use of energy, detergent, water and time. A determination process of the type in question would enable optimal time-related concentration profiles of detergents and bleaches to be maintained in batch washing machines. Optimization of the rinse cycle with a minimum quantity of water in a short time would also be possible without an excessive proportion of the wash liquor remaining behind in the washed fabrics.
Although processes for determining the concentration of detergents and bleaches are known, they are attended by a number of disadvantages which have prevented them from being used on a wide scale in practice. They are generally based on the measurement of physicochemical parameters, for example conductivity and pH value. However, conductivity and pH measurements can be affected by the widely fluctuating introduction of electrolytes and acids or bases with the soiled washing.
It is also known that the concentration of chemical substances in a liquid can be determined by flow injection analysis. In this process, a reagent is added to the liquor in a diluted or undiluted sidestream and the concentration is photometrically determined.
Where flow injection analysis is used to determine the concentration of detergents or bleaches in the wash liquor, other substances which must be ecologically and toxicologically safe often have to be added to the detergent. However, in order to determine the concentration with sufficient accuracy, relatively large quantities of these substances often have to be added. Additional effort is involved in the addition of the reagent to initiate the color reaction. The measuring solutions have to be separately disposed of. The general need for a reduction in the level of manual intervention in the washing process conflicts with the need to replace the spent reagents. Other problems are caused by the cloudiness and suspended particles present in the solution to be measured. In order to avoid interference with the extinction measurement, the particles in question have to be removed beforehand, for example by filtration. Since flow injection analysis cannot take place in the wash liquid itself, an often considerable delay between sampling and measurement has to be accepted.
DE 29 49 254 A1 describes a washing process in which the concentration of a detergent is determined from its fluorescence radiation. However, where several detergents are used in the same wash liquor, their concentrations cannot be individually determined.
Accordingly, the problem addressed by the present invention was to provide a process of the type mentioned at the beginning which would not have any of the disadvantages mentioned above.
DESCRIPTION OF THE INVENTION
According to the invention, the solution to this problem is characterized in that detergents or bleaches which emit fluorescence radiation in different wavelength ranges on exposure to light are used, in that light is transported by optical fibers to measuring points in the wash liquor, the light emitted there is collected and is delivered by the same optical fiber or by a second optical fiber to a receiving and evaluation unit which detects the intensities of the fluorescence radiation in one or more of the different wavelength ranges and determines the concentration of the detergents or bleaches in the wash liquor via a calibration effected with the detergents or bleaches used.
In one advantageous embodiment, the measurement is carried out in the liquor itself. The distance between the point of measurement and the light source and also the receiving and evaluation unit may assume a new value and still does not lead to any time delay. The process may be used for all wash liquors because the optical fibers are also unaffected by chemically aggressive liquids. The use of the process according to the invention is also not limited in regard to pressure and temperature. Existing lines may be modified without significant expense because all that is required are the openings for the optical fibers to pass through. In addition, the process according to the invention is maintenance-free. In general, no other substances need be added to the detergent or bleach. No reagents have to be added for the concentration measurements and there are no measuring solutions to be disposed of. Another advantage is that there is no need for interim calibrations.
The detergent or bleach is preferably exposed to ultraviolet light of visible light. Accordingly, the concentration measurement involves fluorescent ingredients of the detergent or bleach.
The concentration of the detergent may advantageously be determined from the fluorescence radiation emitted by the optical brighteners present in the detergent. On the other hand, however, the concentration may be determined from the fluorescence radiation of alkyl benzenesulfonate present in the detergent.
The process according to the invention is also used with advantage in batch washing machines. These washing machines operate fully continuously or are cycle-dependent. The soiled washing is delivered on conveyor belts or suspended tracks. As it travels through the machines, the washing passes through the individual washing zones, such as wetting, prewashing, clear washing and rinsing, the countercurrent washing principle being applied. Under this principle, the washing process is carried out in a continuously flowing stream which runs in the opposite direction to the washing. In order to minimize outlay on equipment where the process according to the invention is used to determine concentration at several measuring points, it is proposed that the optical fibers associated with the measuring points be connected to a single light source and a single receiving and evaluation unit by a reversing switch.
The process according to the invention affords particular advantages in regard to the introduction and regeneration of the detergent or bleach in the wash liquor. The introduction of the detergent or bleach is preferably controlled by a control system which compares the actual concentration determined with a pre-set concentration.
The invention also enables the rinsing time to be shortened and the amount of rinsing water required to be reduced. In another embodiment of the invention, therefore, rinsing is terminated when the actual concentration determined has fallen below a pre-set concentration.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are described by way of example in the following with reference to the accompanying drawings, wherein:
FIG. 1 shows various sensor systems with which the process according to the invention may be carried out.
FIG. 2 illustrates a batch washing machine with several measuring points for the measurement of concentration.
FIG. 3 shows the dependence of the fluorescence intensity on the concentration of detergent.
FIG. 4 shows the dependence of the fluorescence intensity on the concentration of an alkyl benzenesulfonate solution.
Fluorescent ingredients already present in the detergent or bleach may be used for the fluorescence measurement. However, other fluorescent markers, which are additionally added, may also be used. Similarly, where concentration is measured by determining the change in the state of polarization, substances which bring about such a change, for example sugar, may be added to the detergent or bleach.
DETAILED DESCRIPTION OF THE INVENTION
The sensor arrangements schematically illustrated by way of example in FIG. 1 may be used to measure fluorescence. Referring to FIG. 1a, the light passing from the light source into the measuring solution 1 and the emitted light can be guided through the same optical fiber 2 providing a semi-transparent mirror 3 is arranged between the light source and the receiving unit. However, the transmitted light and the emitted light may also be guided through different optical fibers (FIG. 1b). In the arrangement shown in FIG. 1c, the light emitted from the light source 4 and transmitted into the measuring solution 1 through the optical fiber 2 impinges on a reflector 5 and is detected by the receiving unit 6 via another optical fiber. Separate light emission and transmission paths are also shown in FIG. 1d.
FIG. 2 shows the Voss-Archimedia batch washing machine with a concentration measuring system connected thereto. The washing 7 is continuously transported from left to right by a screw 8. At the same time, a continuously flowing liquor stream runs in the opposite direction to the washing. The concentration of the detergent in the liquor is measured at four measuring points. A reversing switch a connects the optical fibers extending to and from the measuring points to the light source 4 and to the receiving unit 6, so that one light source and detector unit is sufficient even for several measuring points.
In FIG. 3, the fluorescence intensity is plotted in arbitrary units against the detergent concentration in g/1 in aqueous solution. The detergent contains approximately 0.1% by weight of an optical brightener which fluoresces in the wavelength range from 400 to 700 nm on exposure to UV light with a wavelength of 366 nm.
It can clearly be seen from the graph that the concentration of detergent in the liquor can be gauged very accurately from the measured fluorescence intensity.
A corresponding dependence of the fluorescence intensity of an aqueous alkyl benzenesulfonate solution is shown in FIG. 4. The aqueous solution was exposed to UV light with a wavelength of 366 nm and emitted light in the wavelength range from 400 to 700 nm. In this case, too, the direct dependence of the fluorescence intensity on the concentration can clearly be seen.
LIST OF REFERENCE NUMERALS
1 Measuring solution
2 Optical fibers
3 Semitransparent mirror
4 Light source
5 Reflector
6 Receiving unit
7 Washing
8 Screw
9 Reversing switch
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A process for monitoring the concentration level of a detergent or bleach in a washing liquor of an institutional laundry machine by measuring emitted fluorescence radiation in the washing liquor.
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FIELD OF THE INVENTION
The present invention relates generally to a method and apparatus for controlling the temperature of a space, and more particularly to a method and apparatus of establishing an actual heat load for a space under the conditions prevailing at the time based upon information available to a temperature sensor and adjusting the average heating/cooling percentage rate for relatively short duty cycles whereby the actual heating/cooling load during this duty cycle interval may be approximately matched.
BACKGROUND OF THE INVENTION
In most heating/cooling systems the heating/cooling unit is selected for a worse case situation. For example, a heating unit would be selected for the worse case situation, for example, minus 20° C., the actual temperature rise required for the building as compared to the design temperature rise available from the selected unit is a percentage need of approximately 50%. A normal thermostat operation may, in fact, respond by heating the building for half an hour and then being off for half an hour. However, if the cycling interval can be reduced from one hour to 10 minutes, a more uniform output of heat can be obtained which will be more closely matched to the actual heating load for the space for that particular period of time, and this is particularly true when one considers the thermal mass of most space heating systems. This is of particular interest with infrared heating systems whereby a regulated and continuous output of direct infrared radiation is necessary for maintaining comfort levels. A poor mismatch of average fuel rate over a period of a few minutes is usually not a problem for a well-designed space heating system which utilizes streams of hot air convection) or hot water (hydronic) to distribute heat to the point of use; however, it can be a problem with infrared type heating systems, particularly where the comfort level for the occupants is attempted to be maintained with the air temperatue at a lower than normal level. This can be done provided there is sufficient heat received directly by the body of the occupant by direct infrared radiation from the heating system. Since the heating system will be fired only about one-half of the time when the day is 0° C. and will be off one-half of the time, there will be little or no direct radiation during the off time to provide full comfort for the occupants. However, if the off rate can be reduced to a minimal period of time, the occupants of the space will have little perception of variations of temperature.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and apparatus for controlling the temperature of a space which will give the occupants of a space a perception of more uniform heating/cooling. More particularly, it is an object of the present invention to provide a method and apparatus for controlling the temperature of a space wherein the temperature of the space is constantly monitored, normal unit start/stop signals are provided when the temperature of the space attains a designated normal unit start/stop set points, establishing "on" and "off" base time periods and a plurality of unit duty cycles of a fixed relatively short duration, measuring the duration of an off period caused by receipt of a unit stop signal, and incrementally varying the duty cycle by either selecting a duty cycle of a lower unit operational time in the event that the off period exceeds the "off" base period time or selecting a duty increasing cycle of a higher unit operational time in the event that the "on" operational mode caused by a normal unit start signal exceeds the "on" base time period.
By utilizing the method and apparatus summarized briefly above, more uniform and energy efficient heating/cooling may be achieved.
Other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying figures in which one preferred form of this invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram illustrating how the various components of this invention are interconnected.
FIG. 2 is a flow chart illustrating the program embodied within the controller.
FIG. 3 is a controller timing diagram.
FIG. 4 is a table setting forth various duty cycles.
FIGS. 5A and 5B show the typical firing cycles and radiant output, respectively, of a radiant heater when controlled by a normal thermostat without the controller of this invention, the firing cycles representing a 50% demand.
FIGS. 6A and 6B are similar to FIGS. 5A and 5B but show the firing cycles and radiant output of a heater at a 50% demand when the controller of this invention is utilized.
FIG. 7 is a circuit logic diagram.
DETAILED DESCRIPTION
While the following description will describe the method and apparatus of this invention when utilized with periodically fired radiant gas heaters such as the direct ignition type sold under the trademark "Gordon-Ray" by the Roberts-Gordon Appliance Corp., it should be appreciated that this invention may be utilized with other forms of heating and cooling devices, although it has particular application with periodically fired radiant gas heaters.
FIG. 1 illustrates the entire system which includes a heater indicated generally at 10, a conventional heater or furnace relay indicated generally at 12, a pair of temperature sensors or thermostats indicated generally at 14 and 16, respectively, and control means interposed between the thermostats and the heater relay, the control means or controller being indicated generally at 18. While the preferred form of heater is gas fired, its operation is in fact controlled by a switched electrical circuit which is customarily line current of 110 to 120 volts AC.
The heater relay indicated generally at 12 is of standard construction and includes an enclosure 20 which has mounted therein a step-down transformer 22 and a relay indicated by the dash dot line 24. The transformer is capable of stepping down line voltage of 120 volts to 24 volts. The relay 12 includes an actuator 26, which may be a solenoid, and a normally open switch 28 which is capable of being closed in response to actuation by the actuator 26. The enclosure 20 is provided with suitable terminals T 1 through T 8 and suitable lines may be connected to the various terminals. Thus, 120 volt lines L 1 and L 2 are connected to terminals T 1 and T 2 which are in turn connected with the input side of transformer 22. Output lines 30, 32 are in turn connected by means of terminals T 7 and T 8 to the 24 volt output side of transformer 22. Line L 2 may be additionally connected to the heater 10 by means of branch line 34. Similarly, line L 1 may also be connected to the heater through branch line 36, terminal T 4 , switch 28 terminal T 3 and branch line 38.
The temperature sensors 14, 16 are shown in separate but joined together enclosures 40a, 40b. However, they could be mounted in a single common enclosure. While thermostats are shown for the temperature sensors, other forms of temperature sensing devices could be utilized. In the embodiment illustrated a normal temperature thermostat is illustrated which is interconnected with a heater 10, the thermostat including a switch 14 which will be closed when the temperature of the space surrounding the enclosure 40a attains or falls below a designated normal start set point for the unit 10. Similarly, the temperature responsive switch 14 will be opened when the temperature of the space surrounding the enclosure 40a attains or exceeds a designated stop set point for the unit 10. As this is the function of a conventional thermostat, it will not be described further. In addition, a second abnormal temperature sensor or thermostat 16 is provided, which thermostat will close initiating an abnormal temperature setting when the temperature of the space surrounding the enclosure 40b attains or falls below an abnormal set point condition. This thermostat will in turn open after the temperature surrounding the enclosure 40b is no longer abnormal as evident by an increase in temperature to exceed the abnormal set point.
In conventional thermostat design for a heating unit, the designated normal start set point will be set at a certain figure, say for example 66° F. This thermostat will close when the temperature about the enclosure 40a falls below the normal start set point. Similarly, the contacts of the thermostat 14 will open when the space surrounding the enclosure then attains or exceeds the temperature of the designated stop set point.
The enclosures 40a and 40b are provided with terminals T 9 , T 10 , T 11 , and T 12 . Signal lines 42, 44, 46 and 48 are connected respectively to these various terminals.
It should be observed that the structure described up to this point, with the exception of the abnormal temperature sensor 16, is essentially conventional. Thus, in a normal situation the lines 42 and 44 would be interconnected with the 24 volt power supply 30, 32 on the one hand and with the actuator 26 on the other hand. The actuator 26 would cause switch 28 to close when the temperature about the enclosure 40a attains or falls below the normal start set point of the thermostat 14, as the contacts of the thermostat 14 would close at this point. Similarly, current flow through the actuator 26 would be interrupted when the temperature about the enclosure 40a rises the designated stop set point, as the contacts of the thermostat 14 would open at this point causing the switch 28 to open. When the switch 28 is closed, the heater will be caused to be operated; and when it is open, the heater operation will be stopped.
In order to more uniformly heat the space which surrounds the enclosure 40, the controller 18 of this invention is functionally interposed between the temperature sensing means 14 and 16 and the heater relay 12. The control means or controller 18 includes an enclosure 50 in which are mounted various functional elements and interconnecting lines. In addition, a number of plugs are provided, these being identified at P 1 through P 8 . Plugs P 1 and P 2 interconnect the 24 volt power supply with one end of internal lines 52 and 54, the other ends of which are in turn connected to an internal controller power supply indicated at 56. The internal power supply changes the 24 volt input to a 5 volt DC power supply. The power supply 56 is connected to output lines 58 and 60, line 58 being the 5 volt output line, and line 60 being grounded.
Also mounted within the enclosure 50 of the controller is a microcomputer indicated at 62, the microcomputer in turn including a central processing unit (CPU), a read-only memory (ROM) and a random access memory (RAM). An external clock indicated at 64 is suitably interconnected with the CPU of the microcomputer 62. The microcomputer is suitably programmed in a manner which will be discussed below.
A load switch indicated at 66 is also provided within the controller, the load switch being capable upon actuation from the CPU through line 68 of completing a circuit between a branch line 70 and plug line 72 which terminates in plug P 4 . As can be seen from an inspection of FIG. 1, when the load switch closes, a circuit is then completed between the 24 volt lines 52 and 54 through plug line 74, plug P 3 , relay line 76, terminal T 6 , actuator 26, terminal T 5 , relay line 78, plug P 4 , plug line 72, load switch 66, and branch line 70. The line 68 is caused to transmit a signal to load switch 66 in response to signals received from the temperature sensors 14 and 16 and furthermore in accordance with a certain operational procedure or program contained within the microcomputer 62.
As the signals received by the CPU from the temperature sensors 14 and 16 may need to be conditioned for the proper operation of the microcomputer a signal conditioner may be provided, one such signal conditioner being indicated at block 80. The signal conditioner is in turn interconnected with plug P 7 by plug line 82 and with the CPU by a further line 84. In the event that signal conditioning may not be required, the temperature sensor may be connected directly to an input of the CPU as for example by line 86 which extends between plug 52 and a suitable connection on the CPU of the microprocessor. As is customary the various elements within the controller 18 are grounded, and thus the CPU, RAM, ROM, signal conditioner, clock, and load switch all may be grounded as indicated in FIG. 1.
The operation of the system illustrated in FIG. 1 can best be appreciated from an inspection of the flow chart in FIG. 2, the controller timing diagram in FIG. 3, and the duty cycle table set forth in FIG. 4. First, it should be observed that the microcomputer 62 is provided with a program which controls its operation. This program will cause the microcomputer to commence an "on" operational mode in receipt of a start signal from the normal temperature sensor 14 and to comence an "off" operational mode in receipt of a stop signal from thermostat 14. The program will also cause the microcomputer to establish various duty cycles or operational channels, each duty cycle being of the same predetermined length of time. In the embodiment illustrated 10 duty cycles or operational channels are established, these being illustrated in the table of FIG. 4. Channel No. 1 will cause the load switch 66 to be closed 100% of the time during each complete duty cycle of operation. Thus, for a complete duty cycle of 10 minutes, which is that selected for the system shown in FIG. 1, the load switch will be closed 100% of the time. However, duty cycles are only commenced when an "on" operational mode is started, and are terminated when an "off" operational mode is started. Thus, if the microcomputer enters an "off" operational mode seven minutes after the start of the duty cycle, the cycle will be terminated. Similarly, if the microcomputer enters an "off" operational mode 40 minutes after the start of a duty cycle, 4 duty cycles will time out. Channel No. 2 will cause the load switch to be closed 95% of the time during each complete duty cycle. Thus, again with reference to a 10 minute duty cycle, if channel 2 operation is selected, the load switch will be closed 9.5 minutes and will be open 0.5 minutes. Similarly, channel 3 will cause the load switch to be closed during each complete duty cycle of operation 8.5 minutes and to be open 1.5 minutes.
The program, in addition will also establish "on" and "off" base reference periods. The "on" base reference period in the preferred embodiment is 1 hour. The "off" base reference period in the preferred embodiment is 15 minutes.
The program will also cause channel selection to be varied after the operation of the initial cycle in accordance with the program outlined in the flow chart of FIG. 2. Referring now in more detail to the program, the operation of the controller 18 and its microcomputer 62 is initiated customarily by the closing of a line switch which can be switch 88 as shown in FIG. 1. However, operation can also be initiated by any power up condition which could be, for example, resumption of power to the system after a power failure. Initial operation can also be initiated by the receipt of an abnormal unit start signal received from the abnormal temperature sensor 16. The start or reset condition is indicated by block 100 in the flow chart.
Block 110 indicates that various duty cycles or operational channels are established by the program within the microcomputer 62, the duty cycles being 10 minutes long, and also that "on" and "off" base reference periods of 1 hour and 15 minutes, respectively, are established.
Once the controller 18 is powered up or reset the "on" operational mode will be set for operation on channel 1 duty cycle. This is represented by block 120.
Once the initial "on" operational mode of the controller has been set, its operation will not be commenced until the normal temperature sensor 14 sends a unit start signal to the microcomputer 62. It should be noted that in the event that there is a reset, the normal temperature sensor will simultaneously send a unit start signal commencing the "on" operational mode of the controller. The initiation of a start signal is represented by block 130, and the commencement of operation of the "on" operational mode is represented by block 140.
Once the operation of the unit has been initiated by the normal temperature sensor sending a unit start signal, the length of time which the controller is in the "on" operational mode is measured. This is indicated by block 150.
The heater unit will customarily be fired during the operation of the controller in accordance with the selected channel. Thus, when at startup or reset, the heater will be operated during 10 minutes of each duty cycle of 10 minutes or 100% of the time. However, after a number of cycles of operation a differing channel may have been selected by the program, and accordingly the heater may only be operating at a 55% duty cycle (channel 6) wherein it will be fired for 5.5 minutes of each duty cycle and be off 4.5 minutes of each duty cycle. In any event, when the thermostat 14 is satisfied, it will open causing a unit stop signal to be transmitted to the microcomputer 62. This will immediately cause the load switch 66 to open (if not already open) interrupting operation of the unit 10. This is represented by block 160.
Once the unit stop signal is sent by the normal temperature sensor 14, a comparison is made, this comparison being indicated by the decision block 162. If the duration of the unit start signal was longer than the "on" base period of 1 hour, the "on" operational mode is reset by increasing the duty cycle by 1 channel. Thus, for example, if the last channel to have been operated was channel 2, channel 1 operation is then selected. This is represented by block 164. On the other hand, if the duration of the unit start signal was not longer than the "on" base period of 1 hour, then there will be no change in channel selection and this is represented by block 166.
Immediately after the microcomputer 62 receives a unit stop signal from the normal thermostat 14, which signal can be merely an open line in the embodiment illustrated, the microcomputer 62 starts timing the duration of the "off" operational mode. This is indicated by block 170 in the flow chart of FIG. 2. During the time that the microcomputer 62 is in its "off" operational mode the load switch 66 will be held in open condition thereby preventing operation of the heater 10. This condition will prevail until the normal temperature sensor sends a unit start signal which would happen when the contacts of thermostat 14 are closed. This is indicated by block 180.
Immediately after receipt of a unit start signal a comparison is made between the duration of the "off" operational mode and the established "off" base time period. If the duration of the "off" operational mode was longer than the "off" base time period, then the "on" operational mode is reset by decreasing the duty cycle by one channel, for example from 1 to 2. This decision process is indicated by block 182, and the response to a yes answer is indicated by block 184. In the alternative, if the duration of the "off" operational mode was not longer than the "off" base time period, then there would be no change in the channel selection, and this is represented by block 186.
At this point the program loops, and the microcomputer 62 immediately commences operation of the "on" operational mode in the last selected channel and also starts timing the duration of the "on" operational mode, this being represented by blocks 140 and 150.
While the operation of the system described above has been related to a heater, it should again be noted that other forms of units for controlling the temperature of a space could be utilized. For example, the unit 10 could be a refrigeration unit, and the temperature sensors 14 and 16 could respectively sense the normal desired operating range and a high temperature abnormal setting. While various times have been set forth, these are based upon experience using a periodically gas fired radiant heater of the type referred to above. The durations of the duty cycles and the "on" and "off" reference periods have been established with reference to a normal installation of such a heater. Obviously, other periods could be utilized with other forms of heaters or refrigeration units. However, the particular times specified have been found to have beneficial results when employed with the system utilizing the periodically fired gas radiant heater of the type referred to. Because of the thermal mass of locus whose temperature is being modified by the unit 10, it has been found that the "on" base period should be approximately four times the length of the "off" base period.
Referring now to FIGS. 5 and 6, the advantage of this invention when utilized with a radiant heater can be appreciated. Thus, in a normal controlled situation at a 50% demand level for the area about the thermostat the heater would typically cycle on for 15 minutes and off for 15 minutes. As can be seen from FIG. 5B the radiant output of the heater would initially increase to almost a 100% level during the on portion of a firing cycle and then progressively decrease towards a zero output during the off period of time. Thus, within a short period of time after the heater has been turned off it is not putting out a sufficient output to warm the surrounding area. However, when utilizing this invention, as illustrated in FIG. 6, it can be seen that there is a much more uniform output of heat from the radiant heater when the firing cycles and off cycles are of shorter duration. Thus, the heater is constantly putting out heat at levels which approximate a 40%-60% range of potential heater output thus leading to a much more satisfactory heating condition within the area heated by the radiant heater.
In summary, it should be noted that the controller extracts information about the actual demand on the heating system, and it does this by measuring the length of time that the thermostat is satisfied between the calls for heat by the thermostat. This information is then converted by the microcomputer into an adjustment of the duty cycle to automatically adjust the firing time of each base period (10 minutes). This is done in a way to match the firing time in each 10 minute period to equal about 110% of the actual demand. The thermostat 14 will provide the necessary control of the firing time to provide a more precise match of the firing time (heat gain) to the demand (heat loss). The above is accomplished without the use of a sensor to indicate outside temperature as would be required with conventional equipment to perform the same task. Thus, the system will obtain information that is adjusted to the actual conditions or changes such as an open window, extra ventilation, etc.
While the preferred design in which the principles of the present invention have been incorporated is shown and described above, it is to be understood that the invention is not to be limited to the particular details shown and described above, but that, in fact, widely differing means may be employed in the practice of the broader aspects of this invention.
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A method and apparatus for controlling the temperature of a space. The actual heat load for a space under the conditions prevailing at a time is determined based upon information available to a temperature sensor. The average heating/cooling percentage rate for relatively short duty cycles is adjusted based on this information whereby the actual heating/cooling load during this duty cycle interval may be approximately matched. The percentage rate may be overridden in the event an abnormal temperature situation exists. The method and apparatus of this invention has particular application when utilized with radiant heaters.
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BACKGROUND OF THE INVENTION
The invention relates to a shed forming device for a textile machine, such as for example a weaving machine or a knitting machine, provided with at least one shed forming mechanism, comprising a shed forming means provided in order to perform an upward and downward movement, a movable holding element that can be brought by an actuator into a holding position and into a non-holding position, and a stop for the holding element brought into the holding position, while the holding element is foreseen for holding the shed forming means at a fixed height in its holding position.
In the German patent DE-4309983 with reference to FIG. 4, such a shed forming device for a weaving machine is described. This known device comprises two hooks that can be moved upwards and downwards in opposition, which can be held at a fixed height by a respectively rotatably disposed holding element. An upward and downward moving actuator comes each time on the uppermost part of its stroke between the parts of the holding elements located above the rotation spindle in order to turn these, against a spring pressure, into the holding position. A piezoelectric bending element can then freely be brought into a blocking position between the aforesaid parts of the holding elements. When the actuator is no longer between the holding elements the holding elements are held in the holding position by the bending element. The bending element can also be brought into a non-blocking position, so that the holding elements under the influence of the spring turn towards the non-holding position when the actuator is no longer between the holding elements.
Each holding element has an arm extending above the rotation spindle. When a holding element is brought into the holding position the upper extremity of the aforesaid arm is in the movement path of one of the hooks, so that this hook can hook onto the aforesaid extremity, and therefore remains at a fixed height.
Each holding element also has an arm extending under the rotation spindle. When a hook is held by the holding element, a vertically extending lateral face of the latter arm is against a vertical lateral face of a fixed stop.
A hook held by a holding element exerts a downward directed tractive force on the holding element. With the above described device, this tractive force mainly stresses the pivot point of the holding element. This results in an unacceptably high wear and tear of this pivot point.
Another disadvantage is the complexity of this device. For the turning of the holding elements three different parts are after all necessary: the upwards and downwards moving actuator, the bending element and a spring.
One object of this invention is to provide a shed forming device with the characteristics indicated in the first paragraph of this description, which is less complex, and of which the means of attachment of the movable holding elements are less stressed, than with the above described known device.
There are also shed forming devices for weaving machines, with movable holding elements that can be brought into the holding position and into the non-holding position by a piezoelectric bending element. Such a shed forming device, as has been described in the European patent application no. EP-O 544 527, has however as disadvantage that the bending element itself has to provide the necessary contact pressure between the holding element and the hook. This contact pressure is necessary in order among others to prevent the hook from falling from the holding element under influence of the harness stress acting on it. Piezoelectric bending elements however have the disadvantage that the mechanical energy that they can supply through their deforming, is very limited. When the bending elements of this device have to supply a certain additional mechanical energy, for example in order to overcome frictional forces resulting from dirt, they will no longer be in a condition to ensure the necessary contact pressure.
A further object of this invention is to obtain a shed forming device, whereby the aforesaid contact pressure is obtained, without the actuator having to supply any mechanical energy for that purpose.
Finally there are also shed forming devices for textile machines, with fixed holding elements and elastic hooks, whereby piezoelectric bending elements are used as blocking element in order to prevent an elastic hook from hooking onto a holding element. The upwards and downwards moving hook will then however each time rub over the blocking element. This causes on the one hand wear and tear, and on the other hand the pre-tensioning of the harness working together with hooks has to be sufficiently great, in order that the downward tractive force exerted on the hooks would be able to overcome the friction.
Yet another object of this invention is to obtain a shed forming device without the disadvantages of the shed forming devices mentioned in the preceding paragraph.
SUMMARY OF THE INVENTION
The aforesaid objectives are all achieved according to this invention by providing a shed forming device with the characteristics from the first paragraph of this description, and with a holding element that, while holding the shed forming means at the fixed height, is supported by the stop, so that the holding element is held on the stop by the shed forming means.
With this shed forming device, according to the invention, the means of attachment of the holding element are almost not stressed by the downward tractive force exerted by the shed forming means. This force is after all mainly transferred to the stop. Furthermore the device is also simple to construct because of the fact that only an actuator is required for the turning of the holding elements. Furthermore the necessary contact pressure between the shed forming means and the holding element is produced by the hook load itself, so that the actuator does not have to supply any mechanical energy for that purpose. Because of this the device is particularly suitable for working with a piezoelectric bending element.
Furthermore a non-selected shed forming means (i.e. not held at the fixed height) will not during its upward and downward movement come into contact with a part provided for its selection. Because of this wear and tear are limited to a minimum, while the device can operate with a small pre-tensioning of the harness.
A preferred embodiment of the shed forming device according to this invention comprises a rotatably disposed holding element with an eccentric supporting part for supporting the shed forming means.
With this embodiment the downward tractive force exerted by the shed forming means is eccentrically transferred to the holding element, so that the holding element is pulled into a stable position on the stop by the shed forming means.
With a particular embodiment of this shed forming device, for rotating the holding element into the holding position and the non-holding position, the actuator eccentrically grips onto a part of the holding element, which is under the rotation spindle when the holding element is supported by the stop. Because of this the additional advantage is achieved that the actuator also cannot be stressed.
A particular embodiment of the shed forming device has a holding element, that comprises an arm extending upwards from the rotation spindle in every position, with a supporting part bent over away from the rotation spindle. The supporting part lies on the stop and for supporting the shed forming means, is in the movement path of the shed forming means, when the holding element is brought into the holding position.
The shed forming device according to this invention is preferably produced such that the holding element, the actuator, and the stop of each shed forming mechanism are together detachable from the other parts of the device.
The other parts of the device are the shed forming means and for example the parts of a pulley device working together with the shed forming means. The replacement of the elements (the holding element, the actuator and the stop) provided for the selection (i.e. holding at the fixed height) of the shed forming means can occur in a particularly simply and quick manner, by detaching these elements together and by replacing a new set of selection elements.
With the replacement of one or several of the other parts, such as for example a pulley cord or a pulley element of the pulley device, it is also particularly advantageous that the selection elements can be separately detached and, after carrying out the replacement, can be put back.
With the most preferred embodiment of the shed forming device according to this invention the actuator is a piezoelectric bending element.
Piezoelectric bending elements under the influence of an electric voltage adopt a different bending shape depending on the polarity of the applied electric voltage. Piezoelectric bending elements use very little energy. The energy consumption is comparable to the charging energy of a small condenser. Piezoelectric bending elements furthermore also develop no heat.
The disadvantage that these bending elements can only supply a small mechanical energy, does not manifest itself with the shed forming device according to the invention, because of the fact that the bending element does not have to provide the contact pressure between the shed forming means and the holding element.
With yet another embodiment the actuator is an electromagnetic micro-relay. Since the air gap with such a relay is very small, the energy consumption will also be very small, with a minor development of heat as a result. Furthermore the relay only has to be powered for a short time, namely the time that is necessary in order to move the holding element into its stable position on the stop.
The shed forming device can be produced with shed forming mechanisms working together according to claim 8 or 9 in order to enable two positions, respectively three positions of the textile machine threads connected to it.
In a particular embodiment the holding elements, the actuators and the stops of the shed forming mechanisms working together are detachable together from the other parts of the device.
With a specific embodiment the holding elements and the actuators of the shed forming mechanisms working together are supported by a module, whereby they are disposed between two walls of this module, while a part of each holding element can extend through an opening in a respective wall to support the shed forming means, whereby an edge delimiting this opening forms the stop for the holding element.
The shed forming means of the shed forming mechanisms working together and the pulley element working together with these shed forming means can furthermore be movably supported by a separately detachable module, and are disposed between two walls of this module.
If one or several of the selection elements have to be replaced, the first mentioned module is replaced. If the pulley element or a cord working together with it has to be replaced, the last mentioned module is replaced.
These replacements can be carried out easily and quickly. There are shed forming devices in which the selection elements, the shed forming means, the pulley element, and the cords working together with it are provided in one and the same detachable module. In case of defect of one of these parts the complete module is replaced, so that a large number of intact parts are also replaced.
Because of the fact that the various parts of the shed forming device according to this invention are provided in two separately detachable modules, in case of defect of a part, a smaller number of intact parts has to be replaced.
The invention will now be further clarified in the following detailed description of a preferred embodiment thereof. In this description reference is made to the attached figures, of which
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a shed forming device (without the front side walls) for a two-position-open-shed Jacquard machine,
FIG. 2 is a side view of a shed forming device (without the front side walls) for a three-position-open-shed Jacquard machine, and
FIG. 3 is a side view of a part of the shed forming device (without the front side wall) that comprises the holding elements and an electromagnetic micro-relay.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A shed forming device for a two-position-open-shed Jacquard machine (see FIG. 1) according to this invention, includes a first module (1) with walls (2) that enclose an inner space on the sides and underneath. In FIG. 2 the front side wall of the first module (1) has been removed. In two opposite side walls (2) of the module (1) openings (3) are provided. In the inner space of the module (1) two spindles (4) are provided under the openings (2). On each spindle (4) a holding element (5) is rotatably attached. The holding elements (5) are provided with elongated arms that from the respective spindles (4) extend upwards, and which have an upper bent-over part (6). The bent-over parts (6) are opposite the openings (3) and extend in opposite directions to a respective opening (3). The holding elements (5) can turn until they are in a holding position, whereby the bent-over part (6) rests on the lower edge (7) of a respective opening (3). (The holding element (5) depicted on the left in FIG. 1 is in the holding position). This edge (7) forms a stop for supporting the holding element (1). The holding elements (5) can also turn until they are in a non-holding position, whereby they are stopped by a respective stop element (8), that is disposed centrally in the inner space of the module (1). (The holding element (5) depicted on the right in FIG. 1 is in the non-holding position).
A bimorph piezoelectric bending element (9) is disposed under each holding element (5). The bending elements (9) are securely clamped with a lower extremity in an element (10) provided in the lower part of the module (1), that connects the aforesaid opposite side walls (2).
The holding elements (5) also have a short arm (11) that extends along the other side of the spindle (4) in relation to the aforesaid elongated arm. In each short arm (11) a U-shaped groove is provided, whose open side is directed downwards.
The bending elements (9) extend upwards from the element (10), and have their upper extremity in the U-shaped groove in the short arm (11) of a respective holding element (5).
The bending elements (9) can be supplied with electric voltage via electric conductors (12) so that they achieve a first bending whereby they upper extremity brings a holding element (5) into the holding position. This is the case for the bending element (9) depicted on the left in FIG. 1. The bending elements (9) can achieve a second bending by reversing the polarity of the electric voltage, whereby their upper extremity brings a holding element (5) into the non-holding position. This is the case for the bending element (9) depicted on the right in FIG. 1.
The shed forming device also comprises a second module (13) with two opposite side walls (14) between which a pulley element (15) is attached vertically movable. In FIG. 1 the front side wall (14) has been removed. The module (13) has a bottom (16) under the pulley element (15) and two upright arms (17) above the pulley element (15).
The arms (17) extend above the side walls (14) of the second module (13). The upper edges of the side walls (14) and the arms (17) delimit a U-shaped space in which the first module (1) is detachably disposed. Each arm (17) furthermore also includes a vertical guide rail (18) for a respective hook (19).
The guide rails (18) extend to above the openings (3) in the opposite walls (2) of the first module (1).
Each hook (19) has a protruding wing (20) on the back and a protrusion (21) on top on the front. The hooks are movably disposed in the guide rails (18), with their fronts directed towards each other. On both sides of the joined together modules (1), (13) two blades (22) are provided which can be brought into an upward and downward movement in opposition by a drive device (not represented in the figures).
Moreover an upper edge of each blade (22) can grip under a lower edge of the protruding wing (20) of a respective hook (19). The hooks (19) can consequently be moved up and down in opposition by the blades (22). In the upper dead point of their movement the protrusions (21) of the hooks (19) are brought above the holding elements (5).
When the holding elements (5) are in the holding position, their bent-over parts (6) are in the movement path of the protrusion (21) of a respective hook (19).
Each time when a blade (22) is at the end of its upward movement, it can be determined whether the hook (19) working together with the blade (22) has to be held at a fixed height or has to be engaged by the blade (22), during the following movement cycle of the blade (22).
A hook (19) is after all each time brought with its protrusion (21) above the holding element (5). When the holding element (5) is subsequently brought into the holding position, the protrusion (21) will, with the following downward movement of the hook (19), arrive on the top of the bent-over part (6) of the holding element (5). The hook (19) will consequently be supported by the holding element (5) and remain above at a fixed height during the following movement cycle of the blade (22).
At the end of the following upward movement of the blade (22), the blade (22) will take the hook (19) supported by the holding element (5) along upwards to above the holding element (5).
When the holding element (5) remains in the holding position, the hook will again remain above on the holding element (5) during the following movement cycle (as described above).
When the holding element (5) on the other hand is brought into the non-holding position, the hook (19) will be engaged by the blade (22) for the following movement cycle of the blade (22), and therefore first move downwards and subsequently upwards.
The pulley element (15) has a body (23) to which two pulley wheels (24), (25) are rotatably attached above each other. The pulley element (15) is disposed between the side walls (14) of the second module (13), while the body (23) is slidable in a vertically extending groove (26) in those side walls (14).
The hooks (19) are connected to each other by an upper pulley cord (27), which runs round the upper pulley wheel (24) of the pulley element (15), so that the pulley cord (27) attached to the hooks (19) carries the pulley element (15). During the upward and downward movement of the hooks (19) the pulley element (15) remains at a first height. When one of the hooks (19) is held in an upper position, the pulley element (15) will as a result of the hoisting of the other hook (19) be brought up to a second height.
The bottom (16) of the second module (13) is provided with a means of attachment (28), to which one extremity of the lower pulley cord (29) is attached. This lower pulley cord (29) runs over the lower pulley wheel (25) of the pulley element (15) and subsequently extends downwards, where the other extremity is provided in order to form a shed between the threads of a textile machine.
Because of the fact that the pulley element (15) can be brought to two different heights, this is also the case for the hanging-down extremity of the lower pulley cord (29).
By providing a Jacquard machine with a series of shed forming devices as described above, a two-position-open-shed Jacquard machine is obtained. Such a Jacquard machine can for example be used on a weaving machine, for forming a shed between warp threads. The warp threads can be raised by harness cords, which are hung onto a hanging-down extremity of a lower pulley cord (29) of the shed forming device.
A three-position-open-shed Jacquard machine consists of two devices working together: A first device that can be seen in the side view of FIG. 2, and a second device, which is disposed next to the first device, and is therefore not visible in FIG. 2. The second device is identical to the shed forming device according to FIG. 1, without the lower pulley cord (29).
The first device (see FIG. 2) is distinguished from the device depicted in FIG. 1, because of the fact that a reversing wheel (30) is disposed in the second module (13), and because of the fact that the lower pulley cord (29) has another route. The parts from FIG. 2 that are identical to the parts from FIG. 1 are indicated by the same reference numbers.
The reversing wheel (30) is revolvingly attached to an arm (31) that is rotatably attached to the bottom (16) of the second module (13). The arm (31) can rotate in a plane (the plane of the drawing) extending parallel to the side walls (14) of the module (13).
The pulley elements (15) of the two devices working together are movably disposed in respective vertical operating planes. The pulley wheel (30) is preferably diagonally disposed between these operating planes.
One extremity of the lower pulley cord (29) is attached to the bottom (16) of the second module (13) of the first device, runs round the lower pulley wheel (25) of the pulley element (15) of the first device, subsequently runs round the reversing wheel (30), subsequently round the lower pulley wheel (25) of the pulley element (15) of the second device, and finally extends downwards, where the other extremity is foreseen for forming a shed between threads of a textile machine.
It is known how the hanging-down extremity of the lower pulley cord can be brought to three different heights with the hooks (19) of the first and the second device.
For obtaining a four-position Jacquard machine the aforesaid extremity of the lower pulley cord (29) can be attached to a movable grid, which together with one of the blades (22) can be brought to an upward and downward movement.
In FIG. 3 an alternative embodiment of the first module (1) is represented in side view. This module (32) has walls (33) that enclose an inner space on the sides and underneath. (The module is represented in FIG. 3 without the front side wall).
The module (32) is furthermore also provided with openings (37) in two opposite side walls (33) and with two holding elements (34) rotatable round a spindle (42) with an upwardly directed arm that is bent over on top. The bent-over part (35) of each arm lies on the lower edge (36) of a respective opening (37) and extends out of the inner space, when the holding element (34) is brought into a holding position.
Each holding element (34) is furthermore also provided with a first short arm (38) that can be drawn by a respective electromagnetic micro-relay (39) disposed in the inner space in order to turn the holding element (34) into the holding position. Each holding element (34) also includes a second short arm (40) onto which a spring (41) grips in order to turn the holding element (34) into the non-holding position.
Each holding element (34) can hold a respective hook (19) at a fixed height in the same manner as has been described above.
In order to hold a hook (19), engaged by a blade (22), at a fixed height, a holding element (34) is turned into the holding position when the protrusion (21) of that hook (19) is above the holding element (34). With its downward movement the hook (19) arrives with its protrusion (21) on the bent-over part of the holding element (34). The downward tractive force that the hook (19) exerts on the holding element (34) holds the holding element on the stop formed by the lower edge (36) of the opening (37). From then on the relay (39) no longer has to be powered. The tractive force exerted by the hook (19) is after all sufficient in order to prevent the holding element (34) from turning back to its non-holding position under influence of the spring pressure of the spring (41).
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Shed forming device for a textile machine having at least one upwardly and downwardly moving shed forming mechanism. An actuator is connected to a movable holding element for moving the element to a holding position and a non-holding position. In the holding position the element holds the shed forming device at a fixed height. A stop is connected to the element for supporting the holding element when it is in the holding position. Because of this the holding element is held on the stop by the shed forming mechanism. Thus, the contact pressure between the shed forming means and the holding element is produced by the hook load itself allowing for a support for the holding element to remain unstressed.
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FIELD OF THE INVENTION
The present invention relates to an ergonomically improved kayak paddle which has gripping members shaped and oriented to conform to the closed hand of a user and to permit the user to determine the orientation of the paddle by touch alone.
BACKGROUND OF THE INVENTION
Kayak paddles are used to propel small watercraft such as canoes and more typically kayaks. The paddles generally consist of a relatively straight shaft with a blade interconnected on both ends. These type of paddles were originally constructed of wood poles with straight shafts and rudimentary blades nailed or glued to the shaft. With the development of plastics, fiberglass and other synthetic materials, modern kayak paddles are lighter, stronger and have improved geometric shapes to withstand the high degree of force and stress experienced by the paddler in severe whitewater conditions.
Due to the extreme forces, however, the paddles have still been found to break, primarily at the points of interconnection between the paddling blades and the substantially longitudinal shaft. The breaking of a paddle can be not only expensive, but potentially dangerous to a paddler in severe whitewater, where control of the kayak can be completely lost resulting in the capsizing of the kayak or a collision into rocks or other hazards.
Furthermore, modern kayak paddles have gripping areas which are generally concentric in shape and parallel to the axis of the blades when viewed in a cross-sectional plane. This type of geometric configuration can create severe hand and arm fatigue since the gripping area does not naturally conform to the hand or allow proper alignment of the joints and wrists, while making it more difficult for the user to determine the orientation of the kayak paddle blades by touch alone.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a lightweight, durable kayak paddle having superior structural integrity at the points of interconnection between the paddle blades, the gripping area and the substantially straight shaft.
It is a further object of the present invention to provide a gripping area on the kayak paddle which is easier to hold, less stressful on the hands, joints and arms of the user, and which provides a shape which is easily identified and located by touch alone.
Accordingly, in one aspect of the present invention, a lightweight polyurethane, fiberglass and carbon fiber kayak paddle is provided which is comprised of a substantially longitudinal shaft interconnected to gripping members on both ends of the shaft. The gripping members are interconnected on the exterior ends to paddling blades which provide the surface area necessary to push the water and propel the kayak or other type of small watercraft. The gripping members are interconnected to both ends of the shaft at an angle greater than about 0° and less than about 45°, which prevents excessive stress and the likelihood of failure at the interconnection point. More preferably, the gripping members are interconnected to both ends of the shaft at angles between about 5° and 10°, and most preferably the gripping members are interconnected to both ends of the shaft at two different angles in different planes at angles between about 5° and 10°.
In yet another aspect of the present invention, an ergonomically shaped gripping area is provided which substantially conforms to the closed hand of a user gripping the paddle. The gripping members have a cross-sectional geometric shape having a substantially flat bottom surface, a substantially semi-circular shaped rear portion for engaging a palm of a user's hand, and a substantially oval front section for engaging the fingers of the paddler's hand. This geometric configuration allows the user of the kayak paddle to locate the gripping member and determine the orientation of the paddle by touch alone, while reducing fatigue in the arms and hands of a user.
In a further embodiment, the gripping member comprises a central portion which opposes the middle finger of a user of the kayak paddle and adjacent portions which oppose the last finger and thumb of the user. Preferably, the central portion of the gripping member has a greater circumference than the adjacent portions.
It is another object of the present invention to provide a method for making an improved kayak paddle which is less time consuming, more efficient and that allows the blade and paddle portions of the kayak paddle to be attached and molded together to form a homogeneous and structurally sound apparatus. Thus, in another aspect of the invention a method for making a stronger, ergonomically improved kayak paddle is provided which allows for the production of the aforementioned paddle in a more efficient, less time-consuming manner as compared to manufacturing processes for similar products. This process includes the steps of preparing a mold of the specified size and shape for the blade portion of the paddle and subsequently coating the blade mold surface with a non-stick fabric. A predetermined volume of polyurethane or similar foam material is mixed to a specified viscosity and temperature while the blade mold is preheated to a temperature of between about 100° F. and 150° F. More preferably, the blade mold is preheated to a temperature of about 125° F. The foam is then poured into the blade mold and the foam is allowed to cure for a sufficient time to solidify the blade core portion of the paddle. The blade mold is opened and the non-stick fabric is removed to disengage the blade core portion from the blade mold. A center section of the molded blade is then cut out and interconnected to an inflatable bladder. The inflatable bladder and the cut out portion of the blade mold is then covered with a carbon kevlar material and resin is applied to the various layers of carbon kevlar for bonding purposes. The cut out portion of the blade core is then reattached to the blade core and fiberglass in combination with a carbon fiber material used to cover and hence reinforce the blade portion and the interconnected shaft. The combined blade and shaft portion is then placed in a mold and pressure is applied to the shaft portion and the blade portion while the bladder is inflated, which in affiliation with the shaft mold, defines the geometric shape of the shaft portion of the kayak paddle. The shaft and blade are then heated for a sufficient period of time to solidify the resin on the fiberglass and carbon fiber at which time the inflatable bladder is deflated and the shaft and blade portion removed from the mold. As a final step, the shaft and blade portion are sanded or otherwise finished to create a smooth surface devoid of burrs or strands of fiberglass.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of an improved kayak paddle.
FIG. 2 is a top perspective view depicting the shaft, blades and gripping areas and orientation of these components.
FIG. 3 is an end view of the kayak paddle showing the orientation of the paddling blades and angles associated therewith.
FIG. 4 is a cross-sectional view of the gripping portion of the invention shown in FIG. 1-FIG. 3.
FIG. 5 is a cross-sectional top plan view of the gripping portion as identified in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1-5, an apparatus constructed in accordance with an embodiment of the present invention is generally identified by reference numeral 2. As shown, the ergonomically improved kayak paddle 2 is generally comprised of a substantially straight longitudinal shaft 4, gripping members 6 connected on both ends of the shaft and paddle blades 14 connected to the gripping members 6.
As seen in FIGS. 1 and 2, the substantially straight longitudinal shaft 4 has a first end 22 and a second end 24. Both the first end 22 and a second end 24 are interconnected to an interior end of a gripping member 18. The exterior ends 20 of the gripping members 18 are attached to the paddling blades 14 which provide the necessary surface area required to propel the watercraft.
In one aspect of the present invention the substantially longitudinal shaft 4 is adjoined to the interior ends 18 of the gripping members 6 at very subtle angles between about 0° and 45°. More preferably the attachment angle is between about 5° and 10°. Although these subtle angles are not easily seen in the drawings, the gripping members are preferably interconnected to the substantial longitudinal shaft 4 at an offset angle of about 5° in one direction and 10° in another direction. As seen in FIG. 2, the degree of angulation is defined as ⊕ 1 and is measured by extending a centerline through the gripping members 6 and intersecting the substantially straight shaft section 4. Thus, the paddle will have two substantially equal angles where each of the interior ends 18 of the gripping members 6 are interconnected to the substantially straight shaft 4. The second defined angle (not shown in drawings) would extend directly into the page, in the "y" axis.
The attachment angles 16 are predetermined when the mold for making the longitudinal shaft 4 is constructed. These subtle geometric curves provide the paddler with a greater degree of comfort and less arm and hand fatigue as compared to paddles which are substantially straight or have abrupt, high angle offsets or bends between the substantially straight shaft 4 and the blades 14. Perhaps more importantly, the subtle curved design of the attachment angles 16 provides stronger structural integrity to the present paddle, as compared to paddles designed with a high degree of offset, since a major portion of the structural stress occurs at the attachment point between the gripping member 6 and the longitudinal shaft. Thus the kayak paddle of the present invention is capable of withstanding significantly more stress without structural failure as compared to kayak paddles which are designed with a greater offset and angulation.
Referring now to FIG. 3, an end view of a paddle is shown with the blade offset angle ⊕ 1 defined between the blades as numeral 26. The blade offset angle ⊕ 2 is important given that it provides the paddler greater control due to a reduction in the rotation of the paddle between alternating strokes. A paddler can have the blade offset angle ⊕ 1 custom made depending on preference and the physical characteristics of the user. Preferably, the blade offset angle 26 ⊕ 1 is between about 0 degrees and 90 degrees, depending on the preference of the user and the type of conditions for which the paddle will be used. More preferably, the blade offset angle 26 ⊕ 1 is about 45° degrees.
Referring now to FIG. 4, a cross-sectional view of the gripping portion of the present invention is shown with the hand of a paddler depicted in a normal position of use. As seen, the gripping member 6 is generally hollow and comprised of an oval front section 12, a flat bottom portion 8, and a semi-circular rear portion 10. As the gripping member 6 is held within the hand of a paddler, preferably the gripping member 6 conforms naturally to the closed hand. That is, the semicircular rear portion 10 conforms to the palm of the hand when in a gripping position. Likewise, the flat bottom portion 8 of the gripping member 6 conforms to the end of the fingers while the oval front section 12 conforms to the closed fingers of the hand. The cross-sectional oval and egg shape serves two important functions. First, the distinct shape and orientation reduces overall hand and arm fatigue since the hand is closed in its natural position, as opposed to concentric or oblong designs which are unnatural for a closed hand. Furthermore, the distinct shape of the gripping members 6 allows the paddler to determine the position of the kayak paddle and orientation of the blades by touch alone. This factor is important in severe whitewater conditions where a paddler may be capsized in water for extended periods of time or may be in a completely inverted position and attempting to right the kayak. In these situations the paddler is unable to look at the orientation of the paddle and must rely on touch alone to determine the position of the paddle for proper use. In a further embodiment of the present invention, finger grips may be provided so that indents fit each individual finger and are molded directly into the gripping members 6 (not shown).
Referring now to FIG. 5, a view depicting the front view of the gripping area 6 connected to the substantially straight longitudinal shaft 4 is shown. Preferably, the gripping member 6 is constructed with a central portion 30 which substantially opposes the middle finger of a user's hand, and adjacent portions 32 which substantially oppose the user's thumb and small finger. As illustrated, the central portion 30 of the gripping member 6 has a greater circumference than the adjacent portions 32, which helps reduce hand and arm fatigue and allows the user to determine the orientation of the paddle more readily and by touch alone. In a preferred embodiment, the circumference of the gripping area which opposes a user's middle finger has a dimension of about 3.875 inches, while the circumference of the gripping area which opposes the user's thumb and small finger has a dimension of about 3.750 inches.
In another aspect of the present invention, an improved method is provided for fabricating a kayak paddle with greater strength than most commercially available kayak paddles. This method includes the steps of utilizing a mold of a predetermined shape for both the paddle blade 14 and longitudinal shaft 4 sections, the shaft 4 section generally including the gripping members 6 discussed previously. Although the shaft 4 portion and blade 14 portions are constructed initially in an independent fashion, the blade 14 and shaft 4 are assembled and molded together in a final process step which creates a homogenous paddle of improved strength. Thus, fiberglass material extends down the entire length of the shaft and through the paddle blade 14 to within 1-3 inches of the blade tip 34.
Generally, the method includes the steps of utilizing a mold for both the paddle blade 14 section and the shaft 4 section. An adhesive spray such as a 3M 77 is sprayed into the blade 14 mold to allow placement of a non-stick fabric, more commonly known as "peel ply", which is a tightly woven, low permeability polyester fabric manufactured by Precision Fabrics Group, Inc. in Greensboro, N.C. The fabric is utilized to remove the blade 14 from the mold without sticking. A fiberglass reinforcement material is then positioned near the blade tip 14 and edges of the blade. A predetermined volume of a low density foam material such as polyurethane is poured into the preheated blade mold at approximately room temperature. The blade 14 mold is maintained at a temperature of preferably between about 115° F. and 140° F., and more preferably at 125° F. for a period of between about 12 and 15 minutes, or until the foam is sufficiently cured. The mold is then opened and the foam core blade 14 with fiberglass reinforcement removed with the non-stick "peel-ply" type polyester fabric.
A center portion of the paddle blade core 14 is then cut out from the blade base 36 to approximately 1"-3" from the blade tip 34, and more preferably 2 inches. This blade cutout portion is then attached to an inflatable bladder having a shape which allows the bladder to be inserted into a longitudinal shaft 4 mold. The bladder is preferably made of a non-stick synthetic material such as rubber, and more preferably silicone rubber. The bladder and the blade cutout portion are then wrapped with a plurality of layers of fiberglass material which are wet with a resin type bonding material to adhere the various layers of fiberglass together and interconnecting to the paddle blade 14, which has been reattached to the paddle blade cutout portion. For reinforcement, the layers of fiberglass and resin are extended downward over the blade base 36 and to within 1"-3" from the blade tip 34.
The blade 14 and a portion of the longitudinal shaft 4 are then covered with a carbon fiber material such as Hexcel 282, which is manufactured by Hexcel Company in Seguin, Tex. for strength. The entire shaft 4 and blade 14 is then placed into the shaft and blade molds where an external pressure of between about 4 and 6 tons is applied in conjunction with internal shaft pressure of 90 psi at a temperature between about 160° F. and 170° F. for approximately 20 minutes.
The inflatable bladder is then deflated and the interconnected paddle shaft and blade removed from the mold. In one embodiment of the present invention, the kayak paddle is molded in two symmetrical left and right identical sections which are interconnected with a ferrule sleeve which fits within the longitudinal shaft 4 at a midway point between the two paddle blades 14. As a final step, the exterior surfaces of the shaft 4 and blade 14 are trimmed and sanded for a more finished appearance.
While various embodiments of the present invention have been described in detail, it is apparent that further modifications and adaptations of the invention will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention. For clarity, the numbering of the various components identified in the figures are provided herein:
______________________________________02 kayak paddle 20 gripping member exterior end04 longitudinal shaft 22 shaft first end06 gripping member 24 shaft second end08 flat bottom portion 26 blade offset angle10 semi-circular rear portion 28 blade stem12 oval front section 30 central portion14 blade 32 adjacent portion16 attachment angle 34 blade tip18 gripping member 36 blade base interior end______________________________________
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An ergonomically improved kayak paddle and a method for making the same is provided which improves the overall strength of the paddle while substantially reducing hand and arm fatigue for a user. The kayak paddle utilizes non-concentric gripping regions between a substantially longitudinal shaft and paddle blade sections. The gripping regions are interconnected to the shaft at non-abrupt predetermined angles of curvature and in a geometric configuration which reduces structural stress and fatigue at critical portions of the paddle while allowing a paddler to orient the paddle by touch alone.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates generally to the field of drilling wellbores through subsurface rock formations. More particularly, the invention relates to method for removing fluid that has entered the wellbore from subsurface formations outside the wellbore.
[0005] 2. Background Art
[0006] Drilling wellbores through subsurface rock formations includes inserting a drill string into the wellbore. The drill string, which is typically assembled by segments (“joints” or “stands”) of pipe threadedly coupled end to end) has a bit at its lower end. The drill string is suspended in a hoist unit that forms part of a drilling “rig.” During drilling, a specialized fluid (“mud”) is pumped from a tank into a passage in the interior of the drill string and is discharged through courses or nozzles on the bit. The mud cools and lubricates the bit and lifts drill cuttings to the surface for treatment and disposal. The mud also typically includes high density particles such as barite (barium sulfate), hematite (iron oxide), or other weighting agents suspended therein to cause the mud to have a selected density. The density is selected to provide sufficient hydrostatic pressure in the wellbore to prevent fluid in the pore spaces of the rock formations from entering the wellbore. The density is also selected to maintain mechanical integrity of the wellbore.
[0007] Wellbores drilled through subsurface formations below the bottom of a body of water, particularly if the water is very deep (e.g., on the order of 1,000-3,000 meters or more) may require special equipment for effective drilling. An example drilling system for such water depths is shown in FIG. 1 . The drill string 28 extends from a drilling rig (not shown for clarity) and is disposed in a wellbore 14 being drilled through rock formations 12 below the bottom of a body of water 10 such as a lake or the ocean. A wellhead 16 including a plurality of sealing devices collectively called a “BOP stack” is disposed at the top end of a surface casing 14 A cemented in place to a relatively shallow depth below the mud line. A marine riser 26 extends from the upper part of the wellhead 20 to the drilling rig (not shown). The riser 26 usually has auxiliary lines associated with it known as “choke” lines 24 , and a “kill line” 22 . Fluid may be pumped into such lines from the rig (not shown) toward the wellbore 14 or may be allowed to move from the wellbore 14 toward the surface. Valves 18 , 20 control fluid movement at the lower end of the kill line 22 . Corresponding valves 30 , 32 control fluid movement at the lower end of the choke line 24 .
[0008] In the present example, the riser 26 is hydraulically opened to the wellbore 14 below. In order to maintain a hydrostatic pressure in the wellbore annulus 13 that is lower than would be provided if the entire length of the riser 26 were filled with mud, the riser 26 may be partially or totally filled with sea water. See, for example, U.S. Pat. No. 6,454,022 issued to Sangesland et al. As the mud leaves the wellbore annulus 13 (the space between the drill string and the wellbore wall), it is diverted, through suitable valves 34 , 36 to a pump 38 that lifts the mud to the surface through a separate mud return line 40 . Typically, the pump 38 is operated so that the interface between the drilling mud and the water column above in the riser 26 is maintained at a selected level. Maintaining the selected level causes a selected hydrostatic pressure to be maintained in the wellbore 14 .
[0009] The issue dealt with by methods according to the present invention is to safely remove from the wellbore 14 any fluid which enters from the rock formations 12 . Such fluid, by reason of its entry, is at a higher pressure than the total hydrostatic pressure exerted by the mud column in the annulus 13 and the column of sea water in the riser 26 . Methods known in the art for dealing with such fluid entry require “shutting in the well”, meaning that the BOP stack is closed to seal against the drill string 28 , and fluid pumping is stopped. Frequently during such operation, the density of the drilling fluid will be increased by adding more dense, powdered material to the mud. See for example U.S. Pat. No. 6,474,422 issued to Schubert et al. for an example of a kick control method.
[0010] It is also possible that the pressures necessary to be applied to the mud return pump and its connecting lines may be exceeded if conventional kick control methods are used.
[0011] It is desirable to have a method for removing kick fluid from a wellbore that does not require the kick fluid to go through the pump, but maintains well bore pressures at acceptable levels. These pressures must be high enough to keep additional formation fluids from entering the wellbore from one formation, while not exceeding the fracture pressure (pressure that cases wellbore fluids to enter the formation) of other exposed formations, most specifically the formation at the last casing shoe, which is the end of the last installed casing.
SUMMARY OF THE INVENTION
[0012] One aspect of the invention is a method for removing a fluid influx from a wellbore. The wellbore is drilled using a drill string having an internal passage therethrough. The wellbore has a wellhead disposed proximate a bottom of a body of water disposed thereabove. A fluid outlet of the wellbore is coupled to an inlet of a mud return pump. An outlet of the return pump is coupled to a return line to the water surface. A riser is disposed above the wellhead and extends to the water surface. The riser is substantially or partially filled with a fluid less dense than a fluid pumped through the drill string. The method includes detecting the influx when a rate of the return pump increases. Flow out from the well is diverted from the return pump inlet to a choke line when the influx reaches the wellhead. A choke in the choke line is operated so that a rate of fluid pumped into the wellbore is substantially equal to a flow rate through the choke line. Fluid flow from the well is rediverted to the return pump inlet when the influx has substantially left the wellbore.
[0013] In one example, an interface level in the riser between the less dense fluid and the fluid pumped through the drill string is then increased to increase fluid pressure at the bottom of the well. A method according to one aspect of the invention for removing a fluid influx from a subsea drilling wellbore drilled using a pump to return drilling fluid from the wellbore to the sea surface. The fluid influx is observed when an operating rate of the return pump increases. Drilling fluid continues to be pumped through the drill string and the return pump until the fluid influx reaches the wellhead. The return pumping is performed at a rate such that a flow into the wellbore substantially equals a flow out of the wellbore. An intake to the return pump is hydraulically isolated from the wellbore. Flow out of the wellbore is diverted to a choke line. The choke is operated so that the flow into the wellbore substantially equals a flow out of the wellbore. Flow out of the wellbore back to the intake of the return pump when an end of the influx reaches the wellhead. The less dense fluid is pumped down an auxiliary line proximate a bottom end thereof to proximate a bottom end of the choke line. Influx fluid is displaced from the choke line using the less dense fluid.
[0014] In one example, drilling fluid is pumped down the auxiliary line into a lower end of the riser to raise an interface level between drilling fluid and less dense fluid in a riser above the wellhead such that a fluid pressure at the bottom of the well is at least as much as fluid pressure in rock formations penetrated by the wellbore.
[0015] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an example prior art mud lift drilling system.
[0017] FIGS. 2-15 show various elements of a method according to the invention that can be performed using the system shown in FIG. 1 . In the various figures, like components will be identified using like reference numerals.
DETAILED DESCRIPTION
[0018] A well control procedure described herein will enable circulating out a fluid influx (“kick”) from a rock formation when drilling in dual gradient mode through a line auxiliary to a drilling riser, such as a choke line. The procedure is dynamic and never exposes the wellbore to a complete column of drilling mud from the bottom of the well to the surface (in the riser). Such a mud column could exert enough hydrostatic pressure to fracture the formations exposed by the wellbore.
[0019] FIG. 1 , as explained in the Background section herein, represents drilling under normal conditions, wherein no fluid enters the wellbore from any formation exposed by the wellbore. When drilling is under normal conditions, the drilling system may be configured as shown in FIG. 1 , specifically, the riser 26 and choke and kill (“C&K”) lines are filled with seawater. The C&K lines are isolated from the wellbore 14 by keeping its lower control valves 18 , 20 , 30 , 32 closed. The pump inlet valves 34 , 36 are open and the pump 38 is operated to lift drilling mud to the surface. A pump suction pressure sensor SPP measures annulus discharge pressure, typically proximate the intake of the pump 38 . The pressure sensor SPP as well as other pressure sensors described below may be coupled to a controller (not shown) for automatic or semi-automatic control over various components of the system. Alternatively, measurements made by the sensors may be communicated to the system operator for manual operation. Operation of the pump 38 is typically maintained automatically at a set point pressure as measured by the sensor SPP, which operation keeps the mud/seawater interface in the riser 26 at a constant level. The riser 26 is open to wellbore 14 as explained in the Background section herein, and includes sea water therein above the interface. The sea water may extend all the way to the surface or to a selected depth below the surface.
[0020] FIG. 2 shows an example ten barrel volume fluid influx (“kick”) 50 entering the wellbore. Such a kick fills about 100 meters of the wellbore with kick fluid, although the length of the wellbore filled by any particular kick will depend, as is known in the art, on the actual volume of the kick, the diameter of the drill string and the diameter of the wellbore. It can be observed that the pump 38 speed and horsepower output will increase in response in order to move the extra fluid volume resulting from the fluid influx (kick). The system operator may determine from observation of the pump speed and/or power measured by sensors that a kick has entered the well. Generally, the pump speed and/or power measurement increases due to the kick 50 because the pump 38 response to the extra fluid volume. As the kick enters the wellbore it may cause movement of the mud/seawater interface in the riser upward; this will have the effect of increasing the SPP reading (more mud, less water in the riser). However, the control program, having sensed this increase in pressure will speed the pump 38 up and restore the level to what is was (the level only changes an inch or two) prior to the kick, This will then restore SPP back to what it was. Once it is observed that a kick is occurring from the change in pump speed and/or power the SPP setpoint may be changed to increase pressure. This has the effect of slowing the pump 38 so that it supports less of the column of fluid in the mud return line adding pressure to the bottom the well and killing the kick. It should be understood that observing the increase in pump speed is only one technique for observing an influx. It is also possible to include a flow meter at a selected position in the mud return line and observe an increase in flow rate. Other techniques for observing the influx will occur to those skilled in the art.
[0021] FIG. 3 shows an initial action in controlling and circulating out the kick 50 . An annular preventer (not shown separately) in the BOP stack 16 is closed around the drill string, thereby isolating the wellbore 14 from the riser 26 . The suction set point pressure may be increased to control the kick 50 . This can be performed by slowing the operating rate of the pump 38 . The pump rate is slowed, and the suction pressure (as measured by the sensor SPP) is increased until the flow rate of mud into well (“flow in”—pumped through the drill string 28 and the rate of flow out of well (“flow out”—through the return line 40 ) are substantially equal. When the flow in and the flow out are substantially equal, no additional fluid is entering well. At such condition, the kick 50 has been stopped or “killed.” It is then necessary to circulate the kick fluid out of the wellbore 14 in a controlled manner. Kick fluid frequently contains gas, in solution and/or as actual bubbles. As the kick fluid moves toward the surface, and hydrostatic pressure is reduced, the gas exsolves from the kick fluid and/or expands in volume. When the flow rates in and out are balanced, the drill string pressure increases, which may be observed by measurements made using a drill string pressure sensor DPP.
[0022] FIG. 4 shows the situation where the rig mud pump (the pump that moves mud through the interior of the drill string) rate is slowed, but the rate is sufficient to keep the drill string full of mud. The kick fluid begins moving up wellbore annulus 13 . At this point, the mud return pump 38 is operated so that the intake pressure (measured by the sensor SPP) is increased to maintain a constant drill pipe pressure (as measured by sensor DPP). The mud return pump 38 should be operated to maintain fluid flow out equal to fluid flow in.
[0023] FIG. 5 shows the kick fluid moving up the wellbore and beginning to expand in volume. During such time, the operator continues to control the mud return pump 38 speed so to maintain constant drill string pressure (measured by sensor DPP) and to cause flow out to be substantially equal to flow in.
[0024] FIG. 6 shows continuing to adjust the mud return pump 38 speed to keep constant drill string pressure. The mud return pump 38 speed is also controlled to maintain flow out matching flow in. At the point shown in FIG. 6 , the kick fluid 50 has reached the BOP stack 16 .
[0025] FIG. 7 shows opening the valves 30 , 32 to the choke line 24 . A variable orifice choke 44 coupled to the surface end of the choke line 24 is operated to maintain fluid pressure at the bottom of the wellbore (bottom hole pressure) substantially constant. Bottom hole pressure may be measured by a sensor (not shown) in the drill string, or may be estimated using the density of the drilling mud, and an hydraulic model that describes the flow system including the drill bit, wellbore walls, drill string and rheological properties of the mud.
[0026] When the valves 30 , 32 to the choke line 24 are opened, the valves 34 , 36 to the intake side of the mud return pump 38 are closed. Thus, further flow out of the wellbore 14 will move up the choke line 24 . When the pump intake valves 34 , 36 are closed, the mud return pump 38 is stopped. It may be necessary that the flow rate into the well will have to be reduced to avoid excess pressure from friction of the fluid in the smaller choke line 24 .
[0027] FIG. 8 shows that the kick fluid 50 is less dense than the mud and seawater, and thus displaces the sea water in the choke line 24 . The surface choke 44 continues to be operated to keep the bottom hole pressure substantially constant. Note that the foregoing is correct for water based drilling fluid. If oil based drilling fluid is used, the oil based fluid will be very close to its original density because any gas will be dissolved in the oil based fluid. Reduction of fluid density will not occur until exsolution of the gas. When this actually takes place varies depending on wellbore conditions.
[0028] FIG. 9 shows that while the kick volume at the bottom of the wellbore was ten barrels, the kick will expand substantially as the kick moves up the choke line 24 to the surface. The choke line 24 unit volume in the present example 0.0197 bbl/ft. Thus, in a system in 10,000 feet water depth, the total choke line volume is 197 barrels.
[0029] FIG. 10 shows the surface choke 44 being operated to keep bottom hole pressure constant as the kick fluid is discharged through the choke 44 . A typical indication that bottom hole pressure is constant is a constant drill string pressure (as shown by sensor DPP).
[0030] FIG. 11 shows restarting the mud return pump 38 . The valves 34 , 36 to the mud return pump 38 inlet are opened, and the valves 30 , 32 to the choke line 24 are also open. The intake pressure set point on the mud return pump 38 , measured by sensor SPP, is set to match the existing pressure at the mud return pump 38 intake The valves 30 , 32 to the choke line 24 are then closed.
[0031] FIG. 12 shows connecting one of the other auxiliary lines, e.g., the kill line 22 to the choke line 24 using bypass lines or internal passages the BOP stack 16 . The valves 30 , 32 at the base of the choke line and the kill line 18 , 20 are then opened. Sea water is pumped from the surface down the kill line 22 , back up the choke line 24 . Such pumping displaces the kick fluid 50 from the choke line 24 .
[0032] FIG. 13 shows that once kick fluid 50 is fully displaced from the choke line 24 , the well choke pressure (which may be measured by sensor CK) is zero. At this point any connection between the boost line 22 and the choke line 24 may be removed or closed. The wellbore 24 is then returned to regular drilling control by the following procedure, which takes into account the higher fluid pressure in the rock formation from which the kick originated.
[0033] FIG. 14 shows pumping mud through the boost line (not shown). The boost line is placed in hydraulic communication with the lower end of the riser 26 . Pumping continues down the boost line until the fluid pressure at the bottom of the riser 26 equals the pressure in the wellbore existing at the BOP stack 16 . This pressure is the existing pressure (measured by the sensor SPP) at the mud return pump 38 intake.
[0034] FIG. 15 shows the annular preventer being opened, the choke line 24 valves 30 , 32 and the kill line 22 valves 18 , 20 being closed, and normal drilling resuming with a new fluid level interface in the riser 26 . The new fluid interface level in the riser 26 , being higher than the interface level shown in FIG. 1 , provides a greater bottom hole pressure than with the interface as shown in FIG. 1 . Thus, formations having higher fluid pressure may be safely drilled without fluid entry into the wellbore 14 .
[0035] It will be appreciated by those skilled in the art that the foregoing method may also be used when no riser connects the wellhead to the drilling unit. In such examples, the wellhead may have affixed to the top thereof a rotating diverter, rotating BOP or rotating control head that directs fluid from the annular space surrounding the drill string 28 to the pump 38 intake. The intake pressure of the pump SPP will be adjusted for the lack of a column of liquid applied to the wellbore annulus in “riserless” configurations. The principle of operation of the method is substantially the same for the riser version shown and explained with reference to the figures as it is in riserless configurations.
[0036] A method according to the invention may enable safe control of fluid influx into a wellbore being drilled without the need to shut in the wellbore and without the need to increase the density of drilling mud to prevent further fluid influx.
[0037] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims.
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A method for removing a fluid influx from a subsea wellbore drilled using a pump to return fluid from the wellbore to the surface. The method includes detecting the influx when a rate of the return pump increases. Flow from the wellbore is diverted from the return pump to a choke line when the influx reaches the wellhead. A choke in the choke line is operated so that a rate of fluid pumped into the wellbore is substantially equal to a flow rate through the choke line. Fluid flow from the wellbore is redirected to the return pump inlet when the influx has substantially left the well.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a nonprovisional of, and claims the benefit of the filing date of U.S. Provisional Patent Application No. 61/286,992, entitled “REAL TIME TRACKING AND MONITORING OF GAS CYLINDERS,” filed Dec. 16, 2009, the entire disclosure of which is incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
[0002] Typically, the management of gas cylinder consumption within a manufacturing plant or a laboratory has been a manual process. Employees are tasked to identify the gas cylinders across a facility, transport them and also monitor the pressure for each gas cylinder attached to the device or process that consumes such gas. This manual process produces many inefficiencies, including lost cylinders, and lost time spent locating misplaced cylinders. But perhaps the greatest inefficiency occurs when a logistical breakdown results in a gas run-out during a lab experiment or as part of a manufacturing process. These gas run-outs could force plants to repeat analytical experiments, shut down critical manufacturing, and in some situations entire plants while additional gas is ordered and shipped. The resulting downtime causes substantial losses in productivity and revenue.
[0003] Because the productivity losses from gas run-outs can be so great, end-users will often pay additional costs to overstock gas cylinder products, and in some circumstances even pay for onsite cylinder management personnel provided by the gas supplier. Gas producers normally charge a cylinder rental fee for each gas cylinder delivered to the end-user, in addition to the gas purchase fee. These rental fees can accrue substantially when the end-user keeps more cylinders on site than is necessary to maintain plant operations. Moreover, stocking a greater number of cylinders increases the chances of a cylinder being lost, resulting in the end-user paying more cylinder replacement fees in addition to the accruing cylinder rental fees. End users face a constant challenge deciding how to determine the correct inventory of gas cylinders to keep on hand at additional cost to avoid the risk of a gas run-out and sustain plant operations.
[0004] End users make more effective decisions about the number of cylinders to stock when they have accurate, timely updates on the current levels of gas cylinder products being utilized and stocked on site. However, the more frequent these updates are required, the more resources that must be spent to gather and report the current gas cylinder inventory. In processes that require employees to manually monitor and report gas pressures for a large number of individual gas cylinder products, frequent updates can be a significant drain on worker resources and are prone to data recording and interpretation errors. Thus, there is a need for new solutions that provide for more frequent monitoring and reporting of gas product inventory in an end-user facility that also do not place a significant additional burden on the end-user's employees. There is also a need for new processes that reduce the number of gas cylinder products which must be inventoried in an end-user's facility without increasing the risk of a gas run-out that adversely affects facility operations. These and other issues are addressed by embodiments of the present invention.
BRIEF SUMMARY OF THE INVENTION
[0005] Methods and systems are described that use Radio-Frequency Identification (RFID) technology to acquire gas cylinder location and gas consumption information in a real-time reporting basis for gas cylinders being stored and used within an end user's facility. These methods and systems address the performance limitations RFID technology has had to track and monitor gas cylinders due to signal attenuation problems when the RFID transceivers are in close proximity to metal cylinder parts. The methods and systems also address challenges integrating RFID with gas cylinders, including the integration of sensors to RFID tags (i.e., integrated RFID sensors) with an enclosure suitable to function within standard gas cylinder transport caps, battery power consumption, and the ability to securely and safely attach standard RFID tags to the various types of gas values used over a range of gas cylinder products, among other challenges.
[0006] The methods and systems described may include automatic sharing of RFID generated location and consumption information with a gas supplier to estimate when replacement gas cylinders should be ordered and shipped to the end-user's facility. These methods and systems allow frequent or even continuous updates of gas inventories at an end-user's facility without a corresponding drain on worker resources. These processes can also significantly reduce the risk of logistical errors and misinterpretation of gas data that may result in a gas run-out, thus permitting the end user to purchase, stock, and utilize the optimum number of gas cylinder products.
[0007] Methods and systems are also described for tracking and locating individual gas cylinders using RFID technology within a gas producer's plant, a storage facility, or an end-user facility, among other sites. These methods and systems provide real time information to track the location of gas cylinders transported between a gas producer facility where the cylinders are filled and an end-user's facility where the cylinders are discharged for storage or use. Providing gas cylinder location information in real time reduces the opportunities for a cylinder being lost or misplaced within an end-user's facility, transported to the wrong facility, or being accidentally removed from the facility.
[0008] One challenge with coupling RFID technology to gas cylinders is the large amount of RF shielding created by the metal used to make the gas cylinder components. Conventional high pressure cylinders are made from relatively thick layers of metal such as stainless steel, carbon steel, or aluminum. Similarly, many cylinder valves that control the release of gas from the cylinder are protected by a gas cylinder transport cap that prevents the valve from impact damage should the cylinder tip over or be mishandled or impacted in an inappropriate manner. The transport cap may be reversibly removed from the cylinder so the cylinder valve can be coupled to a cylinder filing device or end-user application after the cylinder is secured. The cap is also made of a relatively thick metal layer that heavily shields RF emissions. The shielding decreases the signal strength and signal propagation from an
[0009] RFID transmitter attached to the cylinder. These RF shielding problems that are associated with gas cylinders are addressed here with systems, devices, and cylinder designs that improve the transmission of RF signals without compromising the performance, safety, or integrity of the gas cylinder.
[0010] Another challenge is coupling RFID technology with sensors that monitor gas cylinder parameters such as, but not limited to: Cylinder pressure, liquid level, temperature, leak detection, and weigh. These integrated sensors may be used to measure gas levels and gas consumption inside the cylinder in real time. The RFID component may be used to broadcast cylinder measurement information in real time (or periodically updated time) through wireless electromagnetic signals. These signals are received and read by a compatible RFID reader station which is connected via a network system to a software application that interprets to a computer database or some other electronic information system. The received information may be processed and used for decision making events such as when to order a replacement gas cylinder. Systems and devices are also described for RFID integrated gas cylinder monitoring.
[0011] Specifically, embodiments of the invention include a gas cylinder transport cap. The cap has a bottom opening adapted for reversible attachment to a gas cylinder, where the attached cap surrounds a cylinder valve coupled to the gas cylinder. The cap also has a side surface which at least in part defines the perimeter of the bottom opening, where the side surface include a plurality of side openings, and a top surface formed on an opposite side of the cap from the bottom surface, where the top surface includes a top opening. The side openings and an optimally sized and placed top opening improve transmissions of radio-frequency signals from a RFID device attached directly to either the cylinder valve, cylinder neck area or cylinder shoulder area, and are positioned inside the cylinder cap when the cap is attached to the gas cylinder.
[0012] Additional embodiments of the invention may include gas storage and monitoring systems. The systems may include a gas cylinder for storing the gas where the gas cylinder includes a cylinder valve. The systems may further include a sensor fluidly coupled to the cylinder valve where the sensor detects at least one measured characteristic of the gas cylinder and generates cylinder information. The system may still further include an RFID device in electronic communication with the sensor and operable to transmit a wireless signal comprising the cylinder information. Embodiments may also include systems having a plurality of gas cylinders.
[0013] Still additional embodiments of the invention include methods of tracking and monitoring a gas cylinder attached to a gas delivery line without RFID devices installed on the body of the gas cylinder. These methods may include the use of an integrated gas line adapter coupled with RFID devices to provide a method of tracking and monitoring the location and pressure of a gas cylinder or group of gas cylinders, attached as a source of gas to a gas delivery line feeding a process or device. The identification and location data may be communicated to a gas cylinder tracking system that is remotely located from the location of the gas cylinders.
[0014] Further embodiments of the invention may include methods for tracking and monitoring gas cylinders that are utilized within a mobile manifold carriage in various configurations typically containing, but not limited to, about 4 to about 14 cylinders contained and configured within a single manifolded structural carriage assembly to deliver large volumes of gas to a process or device.
[0015] Still further embodiments of the invention include methods of tracking a gas cylinder transported between a first and second location. The methods may include the steps of coupling the gas cylinder to a RFID device, loading the gas cylinder on a transportation vehicle, and reading a gas cylinder identification signal transmitted by the RFID device with an RFID signal reader that translates the signal into gas cylinder identification data. The gas cylinder identification data may be associated with location data provided by a GPS device located in the transportation vehicle. The identification and location data may be communicated to gas cylinder tracking system that is remote from the transportation vehicle.
[0016] Yet more embodiments of the invention include methods of determining inventory usage of gas cylinders. The methods may include the step of measuring gas pressure in a gas cylinder with a sensor coupled to the gas cylinder. The gas pressure information about the gas cylinder may be transmitted using an RFID device in electronic communication with the sensor. The transmitted gas pressure information may be received at a gas cylinder tracking system, and the gas cylinder tracking system may calculate a time when the gas cylinder should be replaced.
[0017] Additional embodiments and features are set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the invention. The features and advantages of the invention may be realized and attained by means of the instrumentalities, combinations, and methods described in the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] A further understanding of the nature and advantages of embodiments of the invention may be realized by reference to the remaining portions of the specification and the drawings wherein like reference numerals are used throughout the several drawings to refer to similar components. In some instances, a sublabel is associated with a reference numeral and follows a hyphen to denote one of multiple similar components. When reference is made to a reference numeral without specification to an existing sublabel, it is intended to refer to all such multiple similar components.
[0019] FIGS. 1A-B show a gas cylinder transport cap with surface openings for advancing and maintaining steady state signal propagation from RFID devices installed within the cylinder valve area of the cylinder according to embodiments of the invention;
[0020] FIG. 2 shows a gas cylinder valve with an integrated sensor device attached according to embodiments of the invention;
[0021] FIG. 3A shows an integrated RFID sensor technology coupled to a gas cylinder that transmits location and operating pressure data from a gas cylinder according to embodiments of the invention;
[0022] FIG. 3B shows the integrated RFID sensor technology positioned on the cylinder valve of the gas cylinder shown in FIG. 3A according to embodiments of the invention;
[0023] FIG. 4A shows an integrated RFID device attached to an in-line gas delivery adapter according to embodiments of the invention;
[0024] FIG. 4B shows another view of the integrated RFID device attached to the in-line gas delivery adapter in FIG. 4A ;
[0025] FIG. 5A shows an integrated RFID device attached to a manifolded section of a mobile cylinder carriage according to embodiments of the invention;
[0026] FIG. 5B shows an RFID device attached to a gas cylinder contained within a mobile cylinder carriage according to embodiments of the invention;
[0027] FIG. 5C shows an RFID device attached to the structural frame of a mobile cylinder carriage that transmits the location of all gas cylinders contained within the mobile cylinder carriage and the location of the mobile cylinder carriage according to embodiments of the invention;
[0028] FIG. 6 shows a fastener mechanism used to secure an RFID device to a gas cylinder valve according to embodiments of the invention;
[0029] FIG. 7 is a flowchart with selected steps in a method of tracking a gas cylinder transported between a first and second location according to embodiments of the invention; and
[0030] FIG. 8 is a flowchart showing selected steps in a method of determining inventory and usage of gas cylinders according to embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Through the application of specialized sensor technology and supporting system hardware installed on pressurized gas containers within an active RFID technology environment, the acquisition of gas consumption data (and other gas attributes) can be facilitated and utilized for providing solutions to reducing supply chain management costs associated with purchasing pressurized gas containers including, but not limited to, order processing, delivery, manual labor and the acquisition and storage of gas products. Examples of methods, systems and equipment include:
Exemplary Gas Cylinder Transport Caps
[0032] FIGS. 1A-B show a gas storage and monitoring system 100 that includes a gas cylinder transport cap 102 that is designed to maintain steady-state RFID signal propagation from an integrated RFID device 103 located inside cap 102 when it is secured to the top of gas cylinder 101 . As shown in FIG. 1B , the top of the transport cap 104 may include one or more openings that reduce electrical interference with the transmission of RFID signals by the RFID device 103 .
[0033] In the particular example shown in FIG. 1B , a plurality of four openings 105 a - d are equally spaced 90° apart around the perimeter of the top of the transport cap 104 . The openings 205 a - d have a slightly rectangular shape. The embodiment shown in FIG. 1B also shows a circular opening at the center of the top of the transport cap 104 .
[0034] The gas cylinder transport cap 102 may be formed to fit standard-sized treaded couplings on the top of a standard-sized gas cylinder. The cap 102 is also formed to accommodate holding the integrated RFID device 103 and any additional sensors and electronics inside the cap. The cap 102 is designed to conform with government safety and impact standards.
Exemplary Gas Storage and Monitoring Systems
[0035] FIG. 2 shows the top portion of another gas storage and monitoring system 200 which includes an integrated RFID gas cylinder valve 202 and RFID device 203 for monitoring and transmitting information about the gas cylinder 201 and its contents. The integrated RFID gas cylinder valve 202 may include sensors that are fluidly coupled to the cylinder valve that measure and detect conditions in the gas cylinder 201 (e.g., pressure, temperature, etc., inside the gas cylinder). The sensors in cylinder valve 202 may be in electronic communication with the RFID device 203 to transmit information about the gas cylinder 201 to the device. The RFID device 203 may itself include integrated sensors and detectors that provide data about cylinder (e.g., the location of the cylinder).
[0036] The RFID device 203 may be operable to wirelessly transmit data signals representing information about the gas cylinder 201 collected from both the sensors in cylinder valve 202 and the RFID device 203 itself This information may include: a unique identifier for the gas cylinder, the location of the cylinder, and the pressure of the gas in the cylinder, and the type of gas in the cylinder, among other information. The information may be transmitted at a predetermined periodic interval (e.g., hourly, daily, weekly, monthly, etc.) and/or transmitted during an event such as moving the cylinder 201 , opening or closing the cylinder valve, etc. In the additional embodiment, the information may be transmitted on a continuous or near continuous basis to monitor the condition of the gas cylinder 201 in real-time.
[0037] For an RFID device 203 that creates and transmits cylinder location data, the device 203 may include integrated electronics to receive and process signals from the Global Positioning System (GPS) or other positioning technology that allows the RFID device 203 to calculate and transmit the location of system 200 . Incorporation of GPS technology permits near real-time tracking of the cylinder in transport. This tracking will become increasingly necessary as government regulations require it for an expanding group of potentially toxic, explosive, or otherwise hazardous gases.
[0038] The wireless signals transmitted by the RFID device 203 may be transmitted according to communication protocols containing specific amplitude and wavelength characteristics that improve signal propagation within the design and structural environment of a gas cylinder transport cap. The protocols facilitate the acquisition of data and continuous monitoring of the gas cylinders in multiple static and dynamic orientations in real-time using the gas cylinder transport cap, and also within environments that normally shield, reduce or limit signal propagation. This communication protocol may also allow the monitoring, acquisition, interpretation and non-interference of data generated from large groups of gas cylinders clustered together.
[0039] FIG. 3A shows another gas storage and monitoring system 300 which includes a gas cylinder transport cap 304 reversibly attached to gas cylinder 301 . The attached cap 304 covers an integrated sensor cylinder valve 302 and RFID device 303 which are located proximate to the cylinder valve at the top of gas cylinder 301 . The attached cap 304 may have one or more openings 305 formed on the side of the cap, as well as a top surface that includes one or more openings that reduce the interference with the wireless electric signals transmitted by integrated sensor cylinder valve 302 and/or the RFID device 303 . The openings in the top of attached cap 304 may also be designed to reduce the interference with wireless electric signals received by the RFID device 303 .
[0040] One or more sensors in valve 302 and/or the RFID device 303 may be operable to measure characteristics of the gas cylinder such as the pressure level of the gas in the cylinder, the temperature of the cylinder, and/or the location of the cylinder, among other characteristics. The sensors may be directly or indirectly in electronic communication with the RFID device 303 so that at least some of the measurement information collected by the sensors is electronically transmitted to the RFID device for wireless transmission. The sensors and RFID device 303 may form a single integrated device coupled to the cylinder valve.
[0041] FIG. 3B shows a close up view of an embodiment of the RFID device 303 that includes sensors that provide information on the condition of the gas cylinder 301 . The RFID device 303 may be positioned adjacent to the cylinder valve 302 that controls the flow of fluids (e.g., gases) to and from the cylinder 301 . The cylinder valve 302 and device 303 are positioned to fit inside a standard cylinder transport cap, such as cylinder transport cap 304 . The RFID device 303 is designed to operate safely as an integrated assembly to facilitate the generation and transmission of wireless signals that may represent location data and other information about the gas cylinder 301 . The body of cylinder valve 302 may incorporate planed, beveled and bored features that maintain the position of the sensors at rest within the valve body and may penetrate the cavity of the gas cylinder 301 to sense and acquire data about the contents of the cylinder (e.g., temperature, pressure, liquid level, moisture level, etc.). The combination of the cylinder valve 302 and RFID device 303 may be designed to incorporate a plurality of sensors to monitor the state of the gas cylinder and its contents.
[0042] FIG. 4A shows another gas storage monitoring system 400 where the gas cylinder 401 is coupled to a gas delivery conduit 405 that delivers the gas from cylinder 401 to an end use application (not shown). The system 400 may include a cylinder valve 402 coupled to the gas cylinder 401 . Coupled to the cylinder valve is an integrated sensor and RFID device 403 . One or more sensors in the integrated device are operable to measure characteristics of the gas (or fluid) stored in the cylinder, such as gas pressure in the cylinder, gas temperature, and downstream gas pressure and flow rate of the gas released from the cylinder. The sensors are electronically coupled to the RFID portion of the device 403 , which can wirelessly transmit data about the characteristics measured by sensors.
[0043] In the embodiment shown in FIG. 4A , the sensor and RFID device 403 are coupled to a gas delivery adapter 404 that allows the gas delivery conduit 405 to be leaktightly coupled to the gas stored in gas cylinder 401 . The adapter 404 may be reversibly coupled to the cylinder valve on the gas cylinder 401 , and may be selected to form a leaktight seal with the adjacent end of the gas delivery conduit 405 .
[0044] As noted above, the RFID device 403 may be activated by the opening or closing of the cylinder valve and/or the release of gas from the gas cylinder 401 . For example when the cylinder valve is opened, the RFID device 403 may start transmitting information about the time the valve was opened, the pressure of the gas in the cylinder, and the pressure and rate of flow of gas downstream of the cylinder valve, among other information. This information may be transmitted to, for example, a monitoring system (not shown) that may be operable to determine when the gas cylinder 401 should be replaced with a new cylinder.
[0045] Referring now to FIG. 4B , another view of the integrated sensor and RFID device 403 attached to the in-line gas delivery adapter is shown. In the configuration shown, the device 403 sits atop a transition assembly 406 that is orthogonally attached to the gas line adaptor 404 . The transition assembly 406 may house one or more sensors used to collect information (e.g., pressure, flow rate, etc.) about the fluids passing through the gas line adaptor 404 . These sensors may then transmit information electronically to the RFID device 403 , which in turn may wireless transmit the information. Sensors may also be integrated directly into the RFID device 403 (e.g., a location sensor).
[0000] Exemplary Gas Storage and Monitoring Systems with Multiple Gas Cylinders
[0046] The systems described may also include systems that report information on the state of a plurality of gas cylinders from and RFID device. FIGS. 5A-C show some exemplary configurations for these multiple-cylinder systems. In embodiments of these systems the sensor and/or RFID devices may be positioned independently of some or all of the gas cylinders, thus eliminating the need to install these devices on each individual gas cylinder in the plurality of gas cylinders.
[0047] FIG. 5A shows a system 500 where a plurality of gas cylinders ( 501 a - b ) coupled to a centralized valve and sensor 502 that is in electronic communication with an RFID device 503 . The cylinders 501 a - b may be held in close proximity by a mobile cylinder carriage 510 that can move, transport, reposition, reorient, etc. the gas cylinders ( 501 a - b ) as a group.
[0048] Each of the individual gas cylinders 501 a - b, may include a cylinder valve 505 a - b that is fluidly coupled to a gas manifold 508 which directs the gases to the centralized valve and sensor 502 . When either of the cylinder valves 505 a - b are opened, measurements about the gases released from cylinders 501 a and/or 501 b, such as the pressure and/or flow rate of released gas, are obtained at the centralized valve and sensor 502 . This and other information about the state of the gas cylinders 501 a - b and carriage 510 (e.g., carriage location information) may be wirelessly transmitted by the RFID device 503 . The centralized valve and sensor 502 may be configured to detect information about the gases supplied from each individual cylinder 501 a - b, and/or may detect averaged information about the plurality of cylinders (e.g., the total pressure and/or flow rate measured at the centralized valve and sensor 502 ). The centralized valve 502 may control the supply of gas from the manifold to a end use application. For example, opening centralized valve 502 may cause a release of gases from some or all the gas cylinders 501 a - b fluidly coupled to the manifold, and held in the mobile cylinder carriage 510 . The sensor on the centralized valve and sensor 502 may detect the average gas pressure in the manifold and provide other information, such as location information about the carriage 510 .
[0049] In additional embodiments, sensors in the centralized valve and sensor 502 may collect gas pressure and time data from each of the plurality of cylinders 501 a - b and transmit the data via the RFID device 503 . When one of the cylinders 501 a - b falls below a threshold low pressure level, the RFID device 503 may transmit the pressure information and/or and alarm or alert indicating that the cylinder should be replaced. A sensor in the RFID device 503 may provide location data about the system 500 that is also transmitted by the RFID device.
[0050] FIG. 5B shows another embodiment of a system 520 where the plurality of gas cylinders 501 a - b are coupled via the gas manifold 508 . In this embodiment, there is no longer a centralized sensor that is independent of a particular gas cylinder. Instead the information about the plurality of cylinders 501 a - b is collected at the integrated valve and sensor 507 attached to the cylinder valve on cylinder 501 b and transmitted via RFID device 503 coupled to the sensor 507 .
[0051] FIG. 5C shows still another embodiment of a system 530 where the plurality of gas cylinders 501 a - b are coupled to a gas manifold. In this configuration, information about the gas cylinders and/or carriage 510 (e.g., location information about the carriage) may be transmitted by RFID devices 512 a - b which are not coupled to any particular gas cylinder or sensor coupled to a gas cylinder valve. The RFID devices 512 a - b may be positioned to allow wireless electronic signals to be sent and received with less interference from other components of the system 530 . In the example shown, the RFID devices 512 a - b are positioned on a post raised above the gas cylinders 501 a - b and the mobile cylinder carriage 510 . In some embodiments, an RFID device 512 a - b may be present for each gas cylinder 501 a - b present in the mobile cylinder carriage 510 , and may transmit information about one associated gas cylinder. In other embodiments, a single RFID device may transmit the information about a plurality or all the gas cylinders grouped with the carriage 510 .
[0052] While FIGS. 5A-C show two gas cylinders 501 a - b being held by the mobile cylinder carriage 510 , embodiments may include more than two gas cylinders. For example, the mobile cylinder carriage 510 may hold, three, four, five, six, seven, eight, nine, ten, twelve, fourteen, sixteen, etc., gas cylinders depending on the size of the cylinders and/or the carriage. The plurality of gas cylinders may be coupled via a gas manifold configured to keep the cylinders fluidly connected to a downstream destination, such as an application that consumes the gas.
Exemplary RFID Fastening Mechanisms
[0053] Turning to FIG. 6 , an embodiment of a monitoring and storage system 600 is shown with a fastener mechanism 604 used to secure an RFID device 603 to a cylinder valve of a gas cylinder 601 . The fastener mechanism 604 shown in FIG. 6 may include a strap that can be securely tightened around a sensor 602 attached to the cylinder valve of the gas cylinder 601 . In the example shown, the strap can be reversibly secured to the RFID device 603 , which permits its removal and replacement from the gas cylinder 601 without having to decouple the sensor 602 from the cylinder valve or gas cylinder 601 itself
[0054] Individual RFID devices 603 may be programmed to transmit information that uniquely identifies the attached cylinder, and may also be coupled to receive and transmit characteristics of the cylinder measured by sensor 602 (e.g., cylinder gas pressure, cylinder location, etc.). In some embodiments, the RFID device may act as a signal amplifier that receives a wireless signal transmitted from the sensor 602 or another RFID device coupled to the gas cylinder 601 and transmits an amplified signal containing at least a portion of the information received from the original signal.
Exemplary Methods
[0055] FIG. 7 is a flowchart with selected steps in a method 700 of tracking a gas cylinder transported between a first and second location. The method 700 may include the steps of coupling the gas cylinder to an RFID device 702 prior to transporting the gas cylinder 704 . The RFID device may be coupled to the gas cylinder at the first location, which may be a facility to prepare gases and/or fill the gas cylinder with the stored gas. The first location may also be a storage site for storing the gas cylinders.
[0056] The method 700 may further include the step of transmitting gas cylinder identification data 706 through the RFID device. The identification data may include an alpha-numeric series of numbers, letters, and/or indicia that identifies the associated gas cylinder and distinguishes the gas cylinder from other gas cylinders being transported between the first and second location. The identification data may be transformed into a wireless signal that can be transmitted by the RFID device.
[0057] The identification data may be associated with location data 708 that provides the location of the gas cylinder. The location data may be provided by GPS electronics that are integrated into the RFID device or some other electronic component attached to (or in close proximity to) the gas cylinder. Alternatively, the location data may be provided by electronics that are part of a transport vehicle that is used to transport the gas cylinder. The identification data and location data may be associated by being combined into a single data set that is wirelessly transmitted by the RFID device. Alternatively, the identification data and the location data may be separately transmitted from the present location of the gas cylinder and associated at another location. Additional embodiments also include transmitting additional information about the gas cylinder, such as the type of gas stored in the cylinder, and the identification of the first and/or second locations, among other additional information.
[0058] The gas cylinder identification data and the location data may be communicated to a gas cylinder tracking system 710 . The gas cylinder tracking system may be located at a site that is remote from both the first location and the second location, and may be used to track the progress of the gas cylinder from the first location to the second location. This tracking information may be communicated to the gas cylinder tracking system by a variety of electronic and/or telecommunications media including E-mail, cellular telephone, facsimile machine, pager device, the Internet, and private data communications networks, among other media. The tracking information may be transmitted in near continuous time to provide real-time or near real-time location information about the cylinder during the trip from the first location to the second location. The gas cylinder tracking system may also provide alerts when the gas cylinder is being routed to the wrong second location, or in transit to a wrong second location.
[0059] The second location may be an end-user's facility where the gas stored in the cylinder is consumed. The facility may be a research facility, and/or a manufacturing facility, among other types of facilities. The gas transported to the second location in the gas cylinder may be a specialty gas, an industrial gas, an electronic gas, and/or a gas used in analytical research, among other types of gases.
[0060] It should be appreciated that the method 700 may also be used to track a plurality of gas cylinders at the same time. For example, the method 700 may be used to track a plurality of gas cylinders held in close proximity to each other by a mobile cylinder carriage. The individual cylinders may be grouped together in the mobile cylinder carriage during transport from the first location to the second location, or they may be grouped together after arriving at either or both of these locations.
[0061] Referring now to FIG. 8 , a flowchart showing selected steps in a method of determining inventory and usage of gas cylinders 800 according to embodiments of the invention is shown. The method 800 may include the step of measuring gas pressure in a gas cylinder 802 . The measurement may be done by a sensor that is coupled to a cylinder valve on the gas cylinder. The method may further include the step of transmitting gas pressure information about the gas cylinder using an RFID device in electronic communication with the sensor 804 . The RFID device may be integrated with the sensor as a single device on the gas cylinder, or it may be a separate device that is also attached to the gas cylinder or in close proximity to the gas cylinder. The same or different sensor coupled to the gas cylinder may also collect and produce additional information about the gas cylinder, such as the location of the cylinder, the downstream flowrate and pressure of gas exiting the cylinder, etc. This additional information may also be transmitted by the RFID device.
[0062] The information transmitted by the RFID device may be received at a gas cylinder tracking system 806 . The tracking system may be located at the same location where the gas in the cylinder is being used, or at a remote location, or both. The gas cylinder tracking system can process the received information and calculate when the gas cylinder should be replaced 808 . The tracking system may also be used to calculate the rate at which gas is being consumed at an end-user's facility and provide an estimate of the amount and frequency with which gas cylinders should be transported to the facility.
[0063] It should be appreciated that while the description of the steps in method 800 above focuses on a single cylinder, the method may also be used to determine inventory and usage of a plurality of cylinders. For example, the RFID device may transmit information from a plurality of cylinders being used in a process at an end-user's facility. The gas cylinders may be grouped in close proximity such as being contained in a mobile cylinder carriage. The plurality of gas cylinders may also be simultaneously supplying gas to an end use process, such that a portion of the cylinders can be replaced with new cylinders without having to interrupt or shut-down the entire process. The method 800 may include alerting process operators and/or the gas cylinder tracking system when one or more of the gas cylinders should be replaced on a manifold that fluidly connects a plurality of the gas cylinders to the end use process.
[0064] Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the invention. Additionally, a number of well-known processes and elements have not been described in order to avoid unnecessarily obscuring the present invention. Accordingly, the above description should not be taken as limiting the scope of the invention.
[0065] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Each smaller range between any stated value or intervening value in a stated range and any other stated or intervening value in that stated range is encompassed. The upper and lower limits of these smaller ranges may independently be included or excluded in the range, and each range where either, neither or both limits are included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included.
[0066] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a process” includes a plurality of such processes and reference to “the cylinder” includes reference to one or more cylinders and equivalents thereof known to those skilled in the art, and so forth.
[0067] Also, the words “comprise,” “comprising,” “include,” “including,” and “includes” when used in this specification and in the following claims are intended to specify the presence of stated features, integers, components, or steps, but they do not preclude the presence or addition of one or more other features, integers, components, steps, acts, or groups.
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A gas cylinder transport cap is described. The cap has a bottom opening adapted for reversible attachment to a gas cylinder, where the attached cap surrounds a cylinder valve coupled to the gas cylinder. The cap also has a side surface which at least in part defines the perimeter of the bottom opening, where the side surface include a plurality of side openings; and a top surface formed on an opposite side of the cap from the bottom surface, where the top surface includes a top opening. The side openings and top opening improve transmissions of radio-frequency signals from a RFID device positioned inside the cylinder cap when the cap is attached to the gas cylinder. A method of tracking a gas cylinder transported between a first and second location is also described. The method may include the steps of coupling the gas cylinder to a RFID device, loading the gas cylinder on a transportation vehicle, and reading a gas cylinder identification signal transmitted by the RFID device with an RFID signal reader that translates the signal into gas cylinder identification data. The gas cylinder identification data may be associated with location data provided by a GPS device located in the transportation vehicle. The identification and location data may be communicated to gas cylinder tracking system that is remote from the transportation vehicle.
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This is a continuation, of application Ser. No. 762,498, filed Jan. 26, 1977, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to a method and apparatus for illumination in obscured ambients and also to the construction of fluid conduits. Various forms of the invention will have particular application to ambients having smoke such as that encountered by firemen in burning buildings. Other forms of the invention may have particular application for increasing visibility in underwater environments wherein mud or other contamination seriously restricts the visibility of a diver. Firemen and other rescue personnel have heretofore been provided with air supply for respiration for some finite time and which does not rely on the ambient air. A major limitation of the ability of firemen and rescuers to accomplish their task at fire scenes is frequently the presence of dense smoke which cannot be penetrated even with high intensity light beams. A similar problem exists where illumination is required in the presence of dust particles and in some cases heavy fog. Also, a similar problem exists in underwater work such as rescue work in muddy water, where existing high intensity light beams are reflected back or obstructed by the contamination within the water.
It is an object of the invention to provide a light assembly and method which will function in an obscured ambient.
It is another object of the invention to provide such an assembly which will improve visibility over a greater distance from the source of the illumination than was previously possible.
SUMMARY OF THE INVENTION
It has now been found that these and other objects of the invention may be satisfied by a light assembly which includes a source of light and a reflector for directing the light in at least one direction. A reservoir of fluid is provided together with means for directing the fluid in a direction parallel to the direction of the light about at least a portion of the circumference of the reflector. The means for directing in fluid will vary with the application. In one form of the apparatus the fluid conduit for directing the fluid about the circumference of the illumination source is dimensioned and configured so as to have a drag induced by fluid flow which is equal to the drag induced by the exterior of the reflector to minimize turbulence.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevational view of the apparatus in accordance with one form of the invention;
FIG. 2 is an elevational view to an enlarged scale of the light portion of the apparatus shown in FIG. 1; and
FIG. 3 is a diagrammatic view illustrating the relationship between a fluid conduit surrounding an obstruction to fluid flow such as the light.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 there is shown the apparatus in accordance with one form of the invention which includes a tank of fluid 10. For applications where the ambient has smoke and air mixed together, it will ordinarily be desirable to use nitrogen as the fluid although the invention contemplates not only the use of compressed gases including clean air and nitrogen as well as flourocarbons which may be held in the tank in the liquid state and allowed to expand to the gaseous state. Tank 10 includes a handle 12 and a valve 14 for selectively allowing the passage of gas out of the tank. The valve 14 is in fluid communication with an enlarged fluid conduit or diffuser 16 which in the preferred embodiment extends around the circumferential region of a reflector and light assembly 18 which is supported by bracket 20. Ordinarily the light will be of the high intensity type although the particular type of light will vary with the application involved. In some forms of the invention it may be desirable to provide vanes 22 which are used to impart a spiral motion to the fluid stream. For other applications the vanes will not be desirable or necessary. The light assembly is powered by battery pack 24 which is selectively connected to the light assembly 18 by a switch 26. Wires 28 complete the circuit between the light assembly 18 and the battery pack 24.
For those applications where it is desirable to see in muddy water and the fluid to be used is a stream of clear water, it will be understood that ordinarily it will be necessary to supply a source of clean water through a hose rather than relying on a tank. In some application, however, it may be possible to use a reservoir of water which may be propelled by a fluorocarbon. Although ordinarily the quantity of fluid necessary to achieve the desired effect ordinarily will be too great in relation to the size of a tank which could ordinarily be carried. The light assembly 18 ordinarily will have a translucent section at least on the right hand side (as viewed, in FIGS. 1 and 2). The shape of the housing for the light assembly 18 will be chosen to minimize turbulence between the light assembly 18 and the fluid conduit 16.
Referring to the view of FIG. 3, fluid enters the fluid conduit 16 from the left and divides around the light assembly 18. To avoid turbulence of the fluid intermediate the light 18 and the fluid conduits 16 it is desirable that the drag produced by the fluid conduit 16 and the light assembly 18 is the same. The lines 30 represent instantaneous positions of the fluid stream as it passes around the light assembly 18. It will be seen that initially the drag in front of the light assembly 18 will be greater than the drag on the wall of fluid conduit 16 and that in the preferred embodiment the drag will be equal as the fluid conduit 16 and accordingly a minimum amount of turbulence is created.
For some applications it will be desirable that the translucent section of light assembly 18 be yellow colored. In some applications the container 10 for the fluid will not be rigidly attached to the fluid conduit 16 surrounding the light as shown in FIG. 1. More specifically for some applications the fluid conduit and light assembly may be disposed on a rescuer's helmet and the fluid source may be disposed remotely such as on the user's back with a flexible hose connecting to the fluid conduit 12. In still other applications and particularly where the apparatus is being used in underwater applications where a substantial volume of liquid will be necessary, the fluid conduit may be supplied by a long hose. It will be understood that the applications described above ordinarily have involved the use of a generally round fluid conduit with a generally round light assembly. The invention also contemplates the use of elongated light assemblies with correspondingly configured fluid conduits. The geometric relationship between the light source and the fluid stream may vary depending upon the application. For some applications it will be desirable that the light beam from the light source be directed directly into the fluid stream. In other applications it will be desirable that the light beam be disposed with the fluid stream surrounding it. For most applications it will be desirable that the fluid stream be of a relatively large volume and low velocity although for other applications higher velocity and lower volume may be desirable.
It will be understood that the reflector may be part of the envelope of an incandescent lamp such as in conventional sealed beam incandescent light assemblies or it may be a discreet member as in halogen lamps to use a small envelope to contain the gas surrounding the filament and a separate reflector.
It will be understood from the foregoing that the apparatus provides a simple and effective apparatus and method for illumination in an obscured environment which has significant application in rescuing people in burning buildings as well as performing underwater work in muddy water.
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A light assembly which includes a source of light and a reflector for directing the light in at least one direction. A fluid is directed about the light to disperse obscuring substances in the ambient surrounding the light. The fluid is directed through a conduit having a contour which minimizes turbulence.
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BACKGROUND OF THE INVENTION
The present invention relates generally to plastic containers and more particularly discloses containers, such as bottles and cans, having improved gas transmission barrier characteristics.
In the food and beverage industry the trend is to move away from packaging perishable products in glass and metal containers and to substitute thermoplastic polymers for the container material. One of the most successful polymers for beverage containers to package beer, wine, and soft drinks has been polyethylene terephthalate (PET). One of the largest markets for PET containers has been in the two-liter carbonated drink field. Another area where PET is expected to be used extensively is in packaging beer and food. In either case, one of the most critical characteristics of the polyester package is the prevention of gas permeation through the wall of the container.
With carbonated soft drinks, the problem with gas permeation is the loss of carbonation (CO 2 gas) from the drink through the wall of the bottle or can. Compared to the small, densely-packed metal and glass molecules, polymer molecules are relatively large and form a porous wall. Even the best polymer known at this time for gas barrier properties, ethylene vinyl alcohol (EVOH), has poor barrier ability when compared to the inorganics such as metals and glass.
On the other hand, beer and food containers preferably should present a good vapor barrier against the ingress of oxygen (O 2 ) into the container because of the accelerated spoilation of the food products caused by the presence of oxygen therein.
While the use of PET two-liter containers has been relatively successful, its use in smaller-sized containers such as half-liter and one-third-liter, is very limited because of the greater surface-area-to-volume ratios of the smaller containers, compared to that of the two-liter container. This proportionate increase in the surface area causes a much more rapid loss of carbonation from and/or ingress of oxygen into the containers and thus decreases the "shelf-life" of the contained product.
There have been several different methods developed in an attempt to increase the "shelf-life" of plastic containers. One of the most common methods involves creating a multi-layered container having a thin barrier layer of a material such as EVOH or polyvinylidene chloride (PVdC) buried between two or more layers of a container polymer such as PET, polypropylene, polystyrene, or PVC. This multi-layer container is difficult and expensive to manufacture since the barrier layers are either expensive (EVOH) or corrosive (PVdC). Also the process for forming a multi-layered material and making a container from it may be much more complex than single-layer processes.
Another method of creating a barriered polymer container is the process known as "dip-coating". In this process a polymer bottle made of a material such as PET, is first formed into its final shape and then the additional step of dipping the container into a coating solution is performed. This solution may be of a barrier material such as PVdC. This process, in addition to adding another expensive step to the container manufacture, also introduces a material to the container that prevents easy recycling. Because of the nature of PVdC, the coating must be removed by solvents before the polymer container can undergo normal recycling. In light of the trend toward compulsive container return laws in various states and a probable federal deposit/return law, all future container designs must be quickly and easily recyclable. Dip-coated bottles do not lend themselves to easy recycling.
The present invention overcomes the deficiencies of the barrier-layer containers and the dip-coated containers by providing a barrier-treated plastic container which provides excellent barrier characteristics, is cheaply and easily treated, and can be completely recycled by conventional recycling techniques without need for removal of dip-coated layers.
This is achieved by impregnating the surface of a normal polymer container with an inorganic material such as a metallic oxide. The impregation is done by gasless ion plating to provide an ultra-thin flexible coating of the inorganic material on the plastic substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the process of the present invention.
FIG. 2 is a magnified cross-sectional schematic view of a coated polymer material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one embodiment of the present invention, a number of one-half liter polyester bottles (polyethylene terephthalate) were placed in a vacuum chamber and a vacuum of about 1×10 -5 Torr was drawn on the chamber. A plating source comprising silicon monoxide (SiO) was vaporized into a metallic oxide vapor. The vapor was ionized into a plasma by an RF energy source and then biased by a DC bias to impinge the substrate (bottle) surface with a sufficiently high energy level to penetrate the SiO ions partially into the substrate polymer. This process is generally the same as that disclosed for metallic and non-metallic substrates in U.S. Pat. Nos. 4,016,389, 4,039,416, Re 30,401, and 4,342,631, which patents are hereby incorporated by reference into this application.
Referring now to FIG. 1, which is a schematic illustration not drawn to scale, disclosed is a vacuum chamber 10 having a substrate holder 11 removably secured therein. At least one plastic bottle 12 is loosely held on the portable fixture 11 below a source of inorganic material 15 held in a vaporizing filament 13. Filament 13 is electrically connected to and supported by a pair of terminals 14. It preferably is a resistance heating element powered by an external AC power supply (not shown). As the coating material 15 held in filament 13 is vaporized by the filament, an ionizing energy, comprising RF (radio frequency), and a biasing DC voltage, are placed on the filament 13 with respect to the substrate holder 11 which is grounded.
As a result of the vaporization of the source material and the ionizing and biasing field created by the DC/RF power supply, a plasma of ionized SiO particles forms between the filament 13 and the substrate holder 11. The bias also accelerates the SiO ions toward the fixture 11a which is located inside the bottle 12. The ions impinge the outer surface of the polyester bottle while traveling at very high velocities and apparently even penetrate partially into the surface of the polymer. An even coating can be obtained by rotating the bottle 12 about one or more of its axes during the impingement cycle.
The impingement cycle is maintained long enough to obtain a coating layer of around 500 angstroms thickness. The result is a clear flexible coating of SiO on the outer surface of the polyester bottle, which it is believed actually penetrates partially into the polymer and plugs the interstices and porosities between the polymer chains. This plugging of the interstices is believed to be a main contributor to the improvement in gas barrier characteristics of the SiO coated container. While 500 Angstroms is considered a good coating thickness, other thicknesses ranging from less than 500 to as high as 5000 Angstroms or more might be used depending on the type of polymer, the container shape, and the size and thickness of the container.
For example a series of PET half-liter bottles were ion-plated with SiO, and the measured CO 2 transmission rate was reduced from ##EQU1## A pressure test was performed over a period of time to determine if flexure during filling or stretching under pressure by the container caused degradation or flaking off of the inorganic material. It was observed that flexure and creep did not significantly degrade the barrier characteristics. Manual flexure of several containers was also performed to test for cracking or flaking of the coating. After these steps were performed, acetone was applied to the coated surface to detect any breaks in the integrity of the coating. Since acetone will not attack inorganics like SiO 2 but is a strong solvent for the polymer, any break in the SiO coating would have allowed the acetone to attack the container polymer. No dissolving of the container was observed after application of the acetone to the outer surface. Thus flexure and creep not only had no effect on the barrier properties they also had no detrimental effect on the surface continuity of the coating.
In addition to the impingement coating of polyesters such as PET it is believed that most other polymers can also be coated successfully. It is also expected that other inorganic materials may be substituted for SiO, for example aluminum oxide and titanium oxide. Most inorganic or metallic oxides should be adaptable to this process. It should also be noted that even though the metals of these plating compounds are generally opaque, their oxides are clear and thus they can be used on both clear and pigmented polymers without affecting the aesthetics of the containers.
Recyclability of the used coated containers is not affected detrimentally because of the extremely small amount of inorganic coating used. Because of its inert nature and presence in small amounts, the coating will not be noticeable in the recycled polymer. The amount of inorganic coating is less than 1% by weight of the polymer in the container. Some containers have inorganic pigments such as titanium dioxide mixed with their polymers in amounts as high as 25% by weight without affecting recyclability; therefore it can be seen how negligible the effect of the coating material is on recyclability using the present invention.
Referring now to FIG. 2, there is illustrated a schematic enlarged illustration of a section of the coated surface indicating how it is believed that the present invention increases barrier properties. In the drawing, which is not an attempt to show true scale, polymer molecules P are shown having long, winding structure which when combined together result in large openings therebetween. Inorganic metalic oxide molecules M, such as Silicon Oxide or Aluminum Oxide, are very small and compact and can be infiltrated into the interstices formed by the long bulky polymer molecules. Because of the vacuum environment around the substrate and the high velocity of impingement during the plating, the inorganic molecules can penetrate deeply into the polymer interstices, giving good binding between the coating and the substrate. A very thin layer, on the order of around 500 Angstroms, of the metallic oxide is applied to the substrate, giving a good barrier in the interstices and having sufficient flexibility to withstand breakage when flexed.
Although a specific preferred embodiment of the present invention has been described in the detailed description above, the description is not intended to limit the invention to the particular forms or embodiments disclosed therein since they are to be recognized as illustrative rather than restrictive and it will be obvious to those skilled in the art that the invention is not so limited. For example it is contemplated that plating materials other than silicon monoxide, aluminum oxide, and titanium oxide can be used. One such material would be tantalum oxide. Also containers other than carbonated beverage bottles would benefit from the present invention, such as beer containers, food containers, and medicine containers. Thus the invention is declared to cover all changes and modifications of the specific examples of the invention herein disclosed for purposes of illustration, which do not constitute departures from the spirit and scope of the invention.
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A container made of an organic resin having improved vapor barrier characteristics is disclosed which achieves an improved barrier by the placement thereon of a thin coating of an inorganic material.
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REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/292,313, filed Jan. 5, 2010, the contents of which are incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] In general, the invention relates to surgical methods, apparatus and kits. More particularly, the invention relates to methods, apparatus and kits for magnet induced compression anastomosis.
BACKGROUND OF THE INVENTION
[0003] Current approaches to surgical treatments for gallbladder disease include open surgical resection, laparoscopic resection, and most recently natural orifice transluminal endoscopic surgery. The risks of these aforementioned techniques include the risks of trans-abdominal and/or transluminal incision (bleeding, infection, perforation, post-operative pain, adhesions, incisional hernia, risks of anesthesia).
[0004] Endoscopic approaches to treat gallbladder or biliary disease have been previously reported. Cholecystogastrostomy creation using endoscopic ultrasound assisted T-tag placement has been described. This technique requires breach of the gastric and gallbladder walls.
[0005] Another technique has utilized neodymium magnets for the creation of magnet compression anastomosis between the common bile duct and the small intestine. However, this treats obstruction of the common bile duct and does not address alternative gallbladder access, nor does it treat gallbladder disease per se.
[0006] A clinical need thus exists for a more minimally invasive procedure and enabling technology which will facilitate the creation of anastomosis between two adjacent organs in the gastrointestinal tract to create an opening between said organs as a replacement procedure for laparoscopic cholecystectomy and/or cholecystogastrostomy.
SUMMARY OF THE INVENTION
[0007] Aspects of the invention relate to materials, apparatus, methods, and kits for creating a fistula, anastomosis, or opening between two adjacent organs. In particular embodiments, the organs are adjacent gastrointestinal organs, such as, for example, the stomach and the gallbladder, the small intestine and the gallbladder, the stomach and the duodenum, or the ileum and the colon.
[0008] The present invention involves the use of a parent magnet and one or more daughter magnets. The parent magnet can be a permanent rare-earth disc or ring magnet (e.g., neodymium-boron-iron (NdBFe) or samarium-cobalt (SmCo), of the appropriate size and/or shape to fit within an endoscope, catheter, or other surgical instrument. Preferably, the parent magnet is a permanent magnet in the form of a disc with a diameter between 0.5 cm to 6 cm, e.g., 1 cm to 3 cm. The parent magnet can include a magnetic portion adapted to generate a magnetic field, and an attachment portion connected to the magnetic portion. In such embodiments, the attachment portion is preferably constructed and adapted to attach the parent magnet to a tissue. For example, the attachment portion can be an endoscopic clip or a suture.
[0009] The daughter magnets or magnetic materials are responsive to the magnetic field of the parent magnet so as to be attracted to the parent magnet through one or more tissues of varying degrees of thickness. The one or more daughter magnets or magnetic materials can include a plurality of ferromagnetic steel ball-bearings or discs. Alternatively, the daughter magnet(s) can be in the form of a magnetic slurry or paste. In a particular embodiment, the one or more daughter magnets are separate magnetic components that are adapted to self-assemble into a larger magnetic structure. The daughter magnet(s) or magnetic materials are appropriately sized and/or shaped for delivery into an organ through an endoscopic instrument and/or system, or a catheter, such as a biliary catheter.
[0010] Both the parent and daughter magnets may be made of a biocompatible material or coated with respective biocompatible coatings.
[0011] One aspect of the invention involves an apparatus for creating a fistula or an anastomosis between two adjacent organs, such as the stomach and the gallbladder, the small intestine and the gallbladder, stomach and the duodenum, or the ileum and the colon. The apparatus includes a parent magnet having a magnetic portion for generating a magnetic field and an attachment portion connected to the magnetic portion for attaching the parent magnet to a tissue, as described herein. The parent magnet is preferably appropriately sized and shaped, as described herein, for fitting within an endoscope or a catheter. The apparatus further includes one or more daughter magnets or magnetic materials, as described herein, that are responsive to the magnetic field generated by the parent magnet so as to be attracted to the parent magnet through one or more tissues of varying degrees of thickness.
[0012] Other aspects of the invention involve the use and placement of a parent magnet or magnetic assembly, as described herein, within a first organ, and the use and placement of one or more daughter magnets or magnetic materials, as described herein, within a second organ adjacent to the first organ. One aspect of the invention involves a method for creating a compression anastomosis between a gallbladder and an adjacent organ, such as the stomach or the small intestine, by placing a parent magnet within the adjacent organ such that it positioned against the proximate wall of the organ that is adjacent to the gallbladder, and introducing one or more daughter magnets or magnetic materials into the gallbladder such that the one or more daughter magnets are magnetically attracted to the parent magnet in the adjacent organ through a defined tissue area between the combined thickness of the two organ walls. The parent magnet may, for example, be introduced by an endoscope, while the daughter magnets or magnetic materials may be introduced into the gallbladder by a catheter, such as a biliary catheter. In alternate embodiments, the daughter magnets or magnetic materials are injected from an adjacent organ (e.g., the stomach or small intestine) into the gallbladder under the guidance of a visualization technology, such as endoscopic ultrasound. For example, endoscopic ultrasound may be used to inject the daughter magnets from the stomach (or the small intestine), through the combined thickness of the stomach wall (or intestinal wall) and the gallbladder wall, into the gallbladder, via the use of Endoscopic Ultrasound, Fine Needle Aspiration (EUS FNA) or other such techniques known to persons skilled in the art of diagnostic and therapeutic endoscopy. Once the parent and daughter magnets have been positioned within their respective organs, they are left in place for a defined amount of time, exerting compressive magnetic forces on the tissue walls, until the tissue necroses and an opening, anastomosis, or fistula is formed between the two adjacent organs.
[0013] Another aspect of the invention involves a method for at least partially inactivating a gallbladder by placing a parent magnet proximate to a wall of an adjacent organ proximate to the gallbladder (e.g., the stomach or the small intestine), introducing one or more daughter magnets or magnetic materials into the gallbladder such that the one or more daughter magnets are magnetically attracted to the parent magnet in the adjacent organ through a defined tissue area between the combined thickness of the two organ walls, allowing the tissue in the defined area to necrose to create an anastomosis between the gallbladder and the adjacent organ, removing the first magnet and one or more second magnets, then selectively inducing gallbladder scarring or damage through the anastomosis. The parent magnet may be introduced by an endoscope, while the daughter magnets or magnetic materials may be introduced into the gall bladder by a catheter, such as a biliary catheter, or injected from an adjacent organ (e.g., the stomach or small intestine) into the gallbladder via the use of Endoscopic Ultrasound, Fine Needle Aspiration (EUS FNA) or other such techniques known to persons skilled in the art of diagnostic and therapeutic endoscopy.
[0014] Kits according to embodiments of the invention may include, for example, a parent magnet as described herein and one or more daughter magnets or magnetic materials as described herein, the one or more daughter magnets or materials being preloaded into an introducing device such as a biliary catheter, or an endoscope such as an endoscopic ultrasound guided fine needle aspiration needle and/or system. Optionally, the kit(s) of the invention can include a grasping snare or pinchers.
[0015] Other aspects, features, and advantages of the invention will be set forth in the description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will be described with respect to the following drawing figures, in which:
[0017] FIG. 1 is a schematic illustration of the gallbladder, generally illustrating the positioning of parent and daughter magnets to create a compression anastomosis, and particularly, the delivery of daughter magnetic material through a biliary catheter to the gallbladder.
[0018] FIGS. 2A-2E are radiographic views illustrating the deployment and retrieval of parent and daughter magnets to create an anastomosis between the gallbladder and the stomach.
[0019] FIGS. 3A-3D are schematic views of a plurality of magnets in the lumen of a catheter, illustrating the process of magnetic self-assembly as the magnets are ejected from the catheter.
[0020] FIG. 4 depicts the arrangement for self alignment between assembled parent and daughter magnets using north/south attractive magnet forces.
[0021] FIG. 5 depicts the arrangement for self alignment between assembled parent and daughter magnets, using “east/west” attractive magnetic forces.
[0022] FIGS. 6A-6D illustrates the concept of “Magnet Self Assembly” in a connected train of magnetic components including a combination of quadruple and dipole components.
[0023] FIG. 7 depicts the extrusion of magnet components arranged in “North-South” arrangement from a fine needle aspiration (FNA) needle.
[0024] FIG. 8 depicts the self-assembly of the magnetic components depicted in FIG. 7 after extrusion from FNA needle and the use of a suture to connect the magnetic components.
[0025] FIG. 9 depicts the deployment of daughter magnets from the stomach into the gallbladder using endoscopic ultrasound, the assembly of the daughter magnets in the gallbladder, and the positioning of a suture in the stomach upon retraction of the endoscopic ultrasound scope.
[0026] FIG. 10 depicts the assembly of daughter magnets in the gallbladder, the deployment and assembly of a parent magnet in the stomach, and the positioning of a suture connecting the daughter magnet assembly and the parent magnet assembly.
[0027] FIG. 11 depicts the magnetic attraction of daughter magnet assembly positioned against the wall of a gallbladder and a parent magnet positioned against an adjacent stomach wall.
DETAILED DESCRIPTION
[0028] The present invention is based on the discovery that an opening may be created in an organ wall or sheet of tissue using magnets. For example, a compression anastomosis or fistula may be created between adjacent abdominal/gastrointestinal organs, such as for example, the stomach and the gallbladder, the small intestine and the gallbladder, the stomach and the duodenum, or the ileum and the colon, using magnets. As used herein, the term “compression anastomosis” refers to the procedure of compressing together the walls of adjacent organs to induce a necrosis/healing process leading to the joining of the lumina of the two organs. The term “fistula” refers to an artificial or abnormal connection or passageway between two epithelium-lined organs that are not normally connected.
[0029] FIG. 1 is a schematic illustration of the gallbladder, showing a parent magnet on one side of the organ wall and a daughter magnet, made of a paramagnetic or ferromagnetic material, on the other side of the organ wall. In the illustrated scenario, the parent magnet resides on or is secured to the stomach wall (not shown in FIG. 1 ). Once installed, the parent magnet and daughter magnet are left in place, with the magnetic attractive forces between them compressing the organ wall or walls, until an opening or anastomosis is created.
[0030] The parent magnet may, for example, comprise a permanent magnet such as a rare-earth disc or ring magnet (e.g., neodymium-boron-iron (NdBFe) or samarium-cobalt (SmCo) attached to a means of mucosal or tissue fixation, such as an endoscopic clip (Olympus QuickClip 2 Hemostatic Clip device, Olympus Corporation, Tokyo, Japan), via a connection, such as suture. In some embodiments, the parent magnet is large enough and of a shape appropriate to create an opening of a size and shape sufficient for an endoscope, catheter, or other surgical instrument to pass through. For example, in the embodiment of FIG. 1 , the parent magnet is in the form of a disc with a diameter between 0.5 cm to 6 cm, but with a preferable diameter of 1 cm to 3 cm. This range of diametric sizes creates an anastomosis large enough to avoid stricture formation that may prohibit endoscopic access.
[0031] One advantage of systems, methods, and kits according to embodiments of the invention is that the parent magnet and the daughter magnet need not be of the same shape, size, or characteristics. For example, the parent magnet may be relatively larger and adapted for delivery using one type or size of instrument, while the daughter magnet or magnets may be of a different form and adapted for delivery using a different type of instrument.
[0032] The one or more daughter magnets or magnetic materials can include a plurality of paramagnetic or ferromagnetic steel ball-bearings or discs having a sufficient size and/or shape for delivery by syringe using air or water pressure through an endoscopic biliary catheter, or a fine needle aspiration needle. For example, The bearings or discs may small enough to be deployed endoluminally via the cystic duct or can be endoscopically injected directly into the gallbladder from an adjacent organ (e.g., the stomach) with the aid of endoscopic ultrasound (EUS) techniques, such as, for example, Endoscopic Ultrasound, Fine Needle Aspiration (EUS FNA). This technique differs from a conventional cholecystogastrostomy using T-tags because the fistula is created by means of magnetic anastomosis rather than endoscopic suturing. In an alternative embodiment, the one or more daughter magnets or magnetic materials can include a magnetic slurry or paste.
[0033] The parent and daughter magnets or magnetic materials would generally be made of a biocompatible material or coated with a biocompatible coating, such as Parylene (Specialty Coating Services (SCS), Indianapolis, Ind.) or other biocompatible coating materials, known to persons skilled in the art.
[0034] The drawings depicted in FIGS. 2A-2E are views illustrating by example, the deployment and retrieval of parent and daughter magnets to create an anastomosis between the gallbladder and the stomach. Specifically, FIGS. 2A and 2B show deployment of paramagnetic 52100 steel ball-bearings into the gallbladder via a biliary catheter. FIG. 2C shows deployment of a NdBFe parent magnet which is endoscopically clipped to the stomach wall. Capture of the bearings, shown in FIGS. 2D and 2E , by the parent magnet, results in apposition of the daughter and parent magnets for the anastomosis.
[0035] In another embodiment of the invention, the daughter magnet or magnetic material, which may be used as the intra-gallbladder component in a stomach-gallbladder anastomosis, comprises a second rare-earth magnet that can be delivered by syringe using air or water pressure through an endoscopic biliary catheter or endoscopically injected into the gallbladder from an adjacent organ (e.g., the stomach) with the aid of EUS FNA methodologies. Since the size of any one daughter element is limited by the cystic duct diameter, this embodiment may utilize a “self-assembling” structure for the magnetic elements, such that after deployment into the gallbladder, the daughter magnet's elements combine to form a larger structure, thus creating sufficient force between the parent and daughter magnets to result in anastomosis. This type of magnetic self-assembly is schematically illustrated in FIGS. 3A-3D , in which a train of daughter magnet components are injected into the gallbladder.
[0036] The components each carry two miniature magnets of variable magnetic polarity (e.g., north (N) or south (S)). In the case of quadrapolar magnets, three magnet component combinations are possible: (i) N-N, (ii) S-S and (iii) N-S (which is equivalent to S-N upon rotation by 180° for symmetric components). The daughter magnet components are small enough to fit through the inner diameter of the biliary catheter or EUS FNA device or FNA needle. Careful selection of the injection sequence can yield a larger planar surface upon self-assembly within the gallbladder than would be possible with any single component. The large daughter magnet in FIG. 3D is assembled by means of the following magnet component sequence (leftmost polarity first): N-S, NN, N-S, N-N. FIGS. 3A-3D represent the simplest example of magnetic self-assembly, and a much larger number of daughter magnet components can be used in practice to provide sufficient mating area with the parent magnet in the small intestine or stomach wall for effective anastomosis.
[0037] The simplest embodiment of a self-assembling magnet results from a dipolar train of free (i.e. unconnected) rectangular or cylindrical magnets extruded into space where the direction of magnetic polarization is perpendicular to the direction of extrusion and the magnetization direction increases in consecutive components by 90° with each. For four rectangular components, where the direction of magnetization of consecutive components is 0°, 90°, 180° and 270° in the plane perpendicular to extrusion, the resultant assembly will be a four-sided rectangle (or a square in the case of identical components), as shown in FIG. 4 . If this first magnetic train comprises the daughter magnet and a second, identical magnetic assembly comprises the parent magnet then mating occurs when the two opposing pole faces (i.e., north and south in the case of FIG. 4 ) come into proximity and the magnetic attractive forces between the two assemblies cause compressive attraction between the parent and daughter magnets. This compressive attraction which acts to compress the intervening gastric and gall bladder walls is theoretically sufficient to produce a leak-free magnetic anastomosis within a period of three to five days. The resultant window of access is accessed by means of needle-knife incision or similar endoscopic cautery, known to persons skilled in the art.
[0038] FIG. 4 shows the arrangement for self alignment between assembled parent and daughter magnets, using purely north/south attractive magnet mating. This configuration is suitable for generating significant compressive force sufficient for the creation of magnetic anastomosis using NdFeB magnetic components. However, to avoid repulsion between the parent and daughter assemblies, the opposing faces (i.e., north/south) need to be in closest contact.
[0039] FIG. 5 shows the arrangement for self alignment between assembled parent and daughter magnets, using what we term “east/west” attractive magnetic forces. This attraction takes advantage of the necessity for magnetic flux lines to form closed paths leading to a strong compressive force between the parent and daughter assemblies. While necessarily less than the compressive force for purely N/S attraction, this configuration may also be suitable for generating significant compressive force sufficient for the creation of magnetic anastomosis using NdFeB magnetic components when the separation distance is small (<1 mm) and high grade magnetic components (e.g., N50 or higher) are employed. The advantage of this configuration is that compression occurs independent of which faces are in contact and self alignment is again achieved.
[0040] FIG. 6 illustrates the concept of “Magnet Self Assembly” in a connected train of magnetic components. When a combination of quadruple and dipole components are employed, a repulsive magnetic force can be used to ensure self assembly. As shown in FIG. 6 , the self assembly is due to the repulsive forces associated with neighboring S poles (indicated by the solid circles) in the upper two components and the neighboring N poles (indicated by the crosses) in the lower two components which, together, drive the assembly into the final four-sided window.
[0041] In an alternate embodiment of the present invention, the intra-gallbladder daughter material may comprise a (super)paramagnetic fluid consisting of iron-oxide particles or a suspension of iron filings. In the presence of the parent magnet, the (super)paramagnetic fluid would be strongly attracted to the parent magnet again, resulting in anastomosis due to the pressure between the two surfaces.
[0042] When external magnets are applied to the ferromagnetic daughter material they can be permanently magnetized to enhance the force of attraction between the parent magnet and the daughter material.
[0043] In the case of a stomach-gallbladder anastomosis, the parent magnet may be placed on the lumen of the small intestine or on the stomach wall using an endoscope that is introduced per-orally. The parent magnet may be fixed to the mucosa of the small intestine or stomach using an endoscopic clip.
[0044] One method for deploying the daughter magnet or magnetic material would involve using the standard Endoscopic Retrograde Cholangiopancreatography (ERCP) technique and fluoroscopy, in which a biliary catheter is introduced over a guidewire into the gallbladder. The ball-bearings or other daughter magnetic material would be delivered to the gallbladder through the biliary catheter using air pressure or liquid pressure provided by syringe. Alternatively, the daughter magnet or magnetic material may be deployed by direct injection from an adjacent organ into the gallbladder with the aid of EUS FNA type systems.
[0045] As previously stated, the magnets may be delivered from one organ (e.g., the stomach) into another adjacent organ (e.g., the gallbladder) via a Fine Needle Aspiration (FNS) needle as illustrated in FIGS. 7 and 8 . In this alternate embodiment, the individual magnets are circular in nature and pre-assembled in a N-S arrangement and injected through the inner lumen of the needle under endoscopic ultrasound guidance. These magnets may also be polarized in a N-S arrangement around the circumference of the magnet to provide for a means of apposition with the parent magnet once positioned. The distal and proximal magnets are pre-loaded with a suture through the distal and proximal eyelets of the distal and proximal magnet elements respectively. Once injected through the needle or biliary catheter, the distal and proximal magnet elements are secured together by tying off the pre-attached suture. As shown in FIG. 9 , the suture is connected at the distal end to the deployed magnetic daughter assembly and runs antegrade through the inner lumen of the aspiration needle or biliary catheter. Once the needle is retracted through the wall of the stomach, the suture remains connected at the proximal end to the parent magnet assembly as shown in FIGS. 9 and 10 . Once the parent magnet has been deployed into the stomach or other organ, both daughter and parent magnets are pushed together to great a tissue apposition between gallbladder and stomach as shown in FIG. 11 .
[0046] Once deployed, magnet fixation is then achieved using EUS-guided T-tag delivery through the gallbladder wall with a second attachment to parent magnet in the stomach or small intestine, ensuring lock-in of parent magnet to the daughter. Such a T-tag procedure is well known to persons skilled in the art of therapeutic endoscopy. Using fluoroscopic guidance, magnetic attraction between the parent magnet and the intra-gallbladder ball-bearings can then be confirmed.
[0047] When the parent and daughter magnets are left in place for a period of time, the compressive forces on the tissue between the two magnets causes the tissue to necrose, leaving an opening surrounded by a fibrotic or collagenous border. After a period of several days (3-15), the creation of an opening, such as a cholecystogastrostomy, can be confirmed by upper endoscopy or another such technique. At that time, the cholecystogastrostomy can be traversed using the upper endoscope for the purpose of mucosal ablation. Mucosal ablation may be achieved using argon plasma coagulation (APC), electrocautery, laser, or instillation of sclerosant (e.g. alcohol or ethanolamine or sodium morrhuate). A prophylactic biliary stent may optionally be placed by endoscopic retrograde cholangiopancreatography (ERCP) prior to gallbladder mucosal ablation.
[0048] The purpose of gallbladder ablation is to induce scarring down of the gallbladder (i.e. functional cholecystectomy). This can be confirmed with a follow-up endoscopy or by radiographic (e.g. oral contrast study) or nuclear medicine study (e.g. biliary scintigraphy or HIDA study).
[0049] Aspects of the invention relate to a surgical kit or kits that contain all the additional, specialized surgical tools used to perform the tasks described above. For example, surgical kits of the invention at least include a parent magnet as described herein, and one or more daughter magnets as described herein, loaded into an introduction device such as a biliary catheter or an endoscopic instrument (e.g., EUS FNA needle and/or system). In one embodiment, the kit(s) of the invention include, but are not be limited to, (i) the parent magnet in a suitable biocompatible enclosure (e.g., Parylene or biocompatible plastic) and (ii) the daughter magnet material, preloaded for deployment. Optionally, the kit(s) of the invention include a grasping snare or pinchers for assisting with the introduction and placement of the parent and/or daughter magnets.
[0050] For embodiments or situations in which the daughter magnet or magnetic material is injected directly into the gallbladder (either by transgastric means or via the small intestine wall), the daughter magnetic material may be preloaded in an EUS FNA injection needle with an outer diameter in the range of 10 Gauge to 25 Gauge, but more preferably in the range of 15 Gauge to 20 Gauge. Deployment of both magnets into the gallbladder and/or stomach can be achieved with the aid of EUS FNA is this instance.
[0051] It should be noted that the present invention is not limited to the clinical applications listed in the afore-described disclosure. The technology as per the disclosed description may also be utilized to achieve an anastomosis between other adjacent organs in both the upper and lower gastrointestinal tracts such as, but not limited to, between the small intestine/gallbladder, the stomach/duodenum and the ileum/colon for bariatric/metabolic purposes. The daughter and parent magnet components may be delivered during simultaneous endoscopy and colonoscopy procedures and mated under fluoroscopy. The afore-mentioned endoscopy and colonoscopy procedures are well known to persons skilled in the art of therapeutic endoscopy.
[0052] While the invention has been described with respect to certain embodiments, the embodiments are intended to be exemplary, rather than limiting. Modifications and changes may be made within the scope of the appended claims.
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Methods and apparatus for creating an anastomosis or fistula between the gallbladder and an adjacent organ are disclosed. First, a parent magnet, typically a permanent magnet, is deployed in the stomach, small intestine, or another organ adjacent to the gallbladder, and a mating daughter material is deployed in the gallbladder in order to create a magnet-compression anastomosis. The gallbladder may then be ablated or otherwise functionally inactivated through the anastomosis. Another aspect of the invention relates to an all-in-one surgical kit that contains all the necessary specialized tools for a surgeon to perform the procedure.
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This is a divisional of application Ser. No. 08/048,696 filed Apr. 16, 1993 now U.S. Pat. No. 5,411,969.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention provides novel dihydroquinolines which are effective as LDL lowering agents and which also have antioxidant capacity.
2. Description of Related Art
It is generally recognized that high blood cholesterol levels are significant risk factors in cardiovascular disease.
It has been established that 3-hydroxy-3methylglutaryl coenzyme A reductase (HMGR) is the first rate limiting enzyme in the biosynthetic pathway for cholesterol, that inhibition of HMGR activity results in a decrease in serum total cholesterol and low density lipoprotein (LDL) cholesterol levels, and that a decrease in serum LDL-cholesterol levels is reflected in a reduction of plasma level of apolipoprotein B. (Brown, et al, J. Lipid Res, 21: 505-517 (1980)).
Tocotrienols have been shown to suppress HMGR resulting in the inhibition of cholesterol biosynthesis and a subsequent drop in LDL cholesterol, apolipoprotein B, thromboxane B 2 , platelet factor 4 and glucose levels. (Wright, et al, A Symposium On Drugs Affecting Lipid Metabolism, Houston, Tex. (Nov. 1989)).
The tocotrienols are structurally related to the tocopherols (vitamin E) and differ only by possessing unsaturation in the isoprenoid side chain. Like the tocopherols, the tocotrienols have antioxidative activity. (Yamaoka, et al, Yukagaku, 34: 120-122 (1985); Serbinova, et al, Free Radical Biology and Medicine, 10: 263-275 (1991)).
Active oxygen species are known to play pivotal roles in the genesis of atherosclerotic plaques, thrombotic episodes, ischemic damage, cancer, aging, dementia, and inflammatory conditions. (Sies, H., Oxidative Stress; Academic Press, New York, (1985); Santrucek, M., Krepelka, J., Drugs of the Future, 13: 73-996 (1988); Steinberg, Circulation, 84: 1400-24 (1991)). Of particular interests are the potential protective effects of antioxidants on lipoproteins, since oxidized LDL is thought to be atherogenic. (Buckley et. al., Drugs, 37: 761-800 (1989); Gwynne et. al., Am. J. Cardiology, 62: 1B-77B (1988)).
PROBUCOL (4,4'-[(1-methylethylidene)bis(thio)]-bis[2,6-bis(1,1-dimethylethyl)] (Lorelco, Marion Merrell Dow)(Formula I) is a hypolipidemic drug, which is also an excellent antioxidant. PROBUCOL inhibits the oxidative modification of LDL both in vitro and in vivo. (Steinberg, Am. J. Cardiol., 57: 16H-21H (1986)). PROBUCOL, however, suffers from bioavailability problems, exhibits only modest reductions in LDL cholesterol, and has undesirable effects on HDL cholesterol. ##STR1##
Esterbauer et al. (Dieber-Rotheneder, et al., J. Lipid Res., 32: 1325-32 (1991)) have examined the oxidative resistance of LDL as a function of oral vitamin E supplementation. While the oxidative resistance of LDL was significantly enhanced during vitamin E supplementation, antioxidant effectiveness varied considerably from subject to subject.
6-Ethoxy-2,2,4-trimethyl-3,4-dihydroquinoline (ETHOXYQUIN, Tokyo Kasai) is widely used as a feed preservative marketed under the name of SANTOQUIN [Formula II]. This antioxidant chemotype has been incorporated into retinoic acid derivatives, and were evaluated as a cancer-prevention agents. (Welch, et al., J. Med. Chem., 25: 81-84 (1982)). The water soluble analogue MTDQ-DA [Formula III] has been investigated as a antiatherosclerotic drug in cholesterol fed rabbits. (Pollak-Bar, et al., Fat Science Proc., 16th ISF Congress, 1059-1067 (1983)). MTDQ-DA mediated fairly modest effects on various lipid parameters, however this compound completely inhibited plaque progression relative to the cholesterol fed rabbit controls. ##STR2##
While the causative factors in the development of atherosclerosis are many, two important ones are elevated serum cholesterol levels and excessive LDL oxidation.
The above compounds do not successfully unite lipid lowering and antioxidant potential. The present describes the successful union of these two pharmacological properties in dihydroquinolines.
SUMMARY OF THE INVENTION
The present invention provides novel dihydroquinolines which combine lipid lowering with antioxidant effectiveness.
An aspect of the present invention provides dihydroquinolines which are useful for cholesterol/lipid lowering in cases of hypercholesterolemia, hyperlipidemia, atherosclerosis and which are also useful to inhibit LDL oxidation.
Another aspect of the present invention provides a pharmaceutical composition which comprises at least one compound of the present invention and a non-toxic pharmaceutically acceptable carrier.
Another aspect the present invention provides a method of treating hypercholesteremia, hyperlipidemia and thromboembolic disorders in birds and mammals, including humans which consists of administering at least one compound of the present invention to a host in need of such treatment.
Another aspect of the present invention provides a method of inhibiting cholesterol biosynthesis, lowering LDL cholesterol, and inhibiting LDL oxidation in birds and mammals, including humans which consists of administering at least one compound of the present invention to a host in need of such treatment.
Another aspect of the present invention provides intermediates useful for making the dihydroquinolines of the present invention.
These and other advantages and objects of the invention will be apparent to those skilled in the art.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides compounds of the general Formula IV ##STR3## wherein X is O, S or CH 2
R 1 is H or ##STR4## R 2 and R 3 are independently H, C 1 -C 5 alkyl, CF 3 , CN, halogen or OCH 3 ,
n is an integer of 0 to 3, and
m is an integer of 1 to 3,
or a pharmaceutically acceptable salt thereof.
As used herein and in the claims, the term "C 1 -C 5 alkyl" is meant to include saturated or unsaturated, branched or straight chain alkyl groups of one to five carbon atoms, including but not limited to methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, and the like. The term "halogen" is meant to include fluorine, chlorine, bromine, and iodine.
Also included within the scope of the present invention are pharmaceutically acceptable acid addition salts, the metal salts, and the solvates of the compounds of Formula IV, which may exist in various tautomeric forms.
The synthesis of the farnesylated dihydroquinoline (4) is shown in scheme I. ETHOXYQUIN (Tokyo, Kasai) (1) was dealkylated with hot hydrobromic acid to give the known crystalline phenol (2). This material was bis-acetylated to give the amide-ester intermediate. Selective deprotection with methanolic KOH gave the amide 3. The side chain could be attached by either coupling through a Mitsunobu-type procedure or by direct alkylation. The Mitsunobu procedure was somewhat capricious, and in general the alkylation proved the better method of synthesis. Removal of the amide protecting group was smooth using excess lithium triethylborohydrate. Use of the amide protecting group was not absolutely necessary, however the yields were significantly better in its presence. ##STR5##
The sulfide 8 was prepared as shown in scheme II. The S-aryl dimethylthiocarbamate 6 was obtained by a Newman-type rearrangement (Newman, et al., J. Org. Chem., 31: 3980-84 (1966)) of O-aryl dimethylthiocarbamate 5. The reaction goes in good yield when catalyzed with p-toluenesulfonic acid under strictly oxygen-free conditions. N-Protection is absolutely necessary in this case as the corresponding aniline-thiol is very unstable. The dimethylthiocarbamate 6 is unmasked with sodium methoxide in methanol to give thiol 7. The alkylation and deprotection were done as described in scheme I. ##STR6##
Synthesis of the methylene-linked analogue of compound 4 can be accomplished via the sequence shown in scheme III. The dihydroquinoline is obtained from the iodine catalyzed reaction of aniline 9 and acetone following a general procedure. (Org. Syn. Coll., 3: 329). The farnesylethyl side chain is attached by alkylation to the sulfone moiety. The nitrogen must be protected during this step to avoid decomposition under basic conditions. The reductive cleavage of the sulfone and super-hydride removal of the amide were smooth, and yielded compound 11 as indicated in scheme III. ##STR7##
The route to 1,2-dihydro-2,2,4-trimethyl-6-[[5-methyl-7-[3-(trifluoromethyl)phenyl]-4(E)hexenyl]oxy]quinoline (18) is shown in scheme IV, and follows a similar strategy as depicted in scheme III. Starting with 5-methyl-4-hexenal, (Marbet, et al., Helv. Chim. Acta, 50: 2095-3000 (1967)) reduction, alcohol protection, and ozonolysis proceeded smoothly to give the 4-silyloxybutanal 12. The Horner-Emmons olefination of 12 gave a 10:1 mixture of E:Z isomers, which could be chromatographically separated. The purified E-enoate 13 was reduced in a 1,2-fashion with dibal-H to give the allylic alcohol 14. The alcohol was converted into the chloride 15 and coupled with the lithium salt of sulfone 10. The toluenesulfonyl activating group was removed with sodium amalgam in buffered methanol and the crude material was then treated with fluoride to give the alcohol. The alcohol was converted into the primary iodide 17 by a standard Finklestein procedure. Coupling of iodide 17 to the N-acetyl dihydroquinoline 3 under basic catalysis followed by amide removal proceeds smoothly to give the final target compound 18. ##STR8## HepG2 Cell Culture Moldel
The human hepatoma HepG2 cell culture model was employed to compare the intrinsic activities of the representative compounds of the present invention relative to the tocotrienols. HepG2 cells were incubated with the indicated compounds for 4 hours at 10 μM. Cholesterol synthesis was assayed by 16 C-acetate incorporation over the final hour of incubation, and HMG-CoA reductase suppression (specific activity) was assayed in the microsomal fraction isolated from parallel cultures at the end of the 4 hour incubation. Time course studies (not shown) indicated that 4 hours preincubations provided maximal suppression of sterol synthesis. The results are shown in Table I.
Table I______________________________________ Percent of ControlCompound Cholesterol HMGR10 μm Biosynthesis Suppression______________________________________γ-Tocotrienol 29 65 4 48 40 8 3 N.T.11 89 N.T.18 42 N.T.______________________________________ N.T. = Not Tested
In Vivo Evaluation of Synthetic Analogues in Normocholesterolemic Chickens
Hypocholesterolemic activity was evaluated for representative compounds of the present invention using γ-tocotrienol as a control in normocholesterolemic chickens. Newborn male chicks (6-10 for each group) were raised on a standard corn-soybean-based control diet for two weeks and then were switched to either control or experimental diets for four weeks. Drug treatment consisted of the addition of test compound to the corn-soybean-based. At the end of the feeding period, all the birds were fasted (about 36 hours) and refed (about 48 hours) to induce cholesterolgenic enzymes prior to sacrifice. The specific activity of HMG-CoA reductase, total serum cholesterol levels, and HDL/LDL cholesterol pools were examined (Table II).
Table II______________________________________Effects of Compounds of the present invention on LipidParameters in Male ChickensOrally dosed for 4-weeks at 4 mg/kg/day Values Given as % of ControlCompound Tot.-C LDL-C HDL-C HMGR______________________________________γ-Tocotrienol 76.3 54.8 87.0 N.T.4 65.9 45.3 89.0 83.88 100.9 99.1 98.2 N.T.18 61.2 26.0 93.8 66.4______________________________________ N.T. = Not Tested
Antioxidant Evaluation
There are a number of ways in which one can evaluate a biological antioxidant. (Halliwell, Free Rad. Res. Comms., 9: 1-32 (1990)). The ability of test compounds to inhibit the oxidative modification of LDL is what is most relevant here. (Bedwell, et al., Biochem. J., 262: 707-12 (1989)). The oxidative modification of LDL has been examined in vitro, using both copper and cellular (enzymatic) mediated processes. Esterbauer et al. have developed a conjugated diene assay for the measurement of LDL Oxidation. (Esterbauer, et al., Free Rad. REs. Comms., 6: 67-75 (1989)). The oxidation of polyunsaturated lipids causes the conjugation of double bonds that can be quantitatively measured spectrophotometrically. The conjugated diene assay appears to be superior to older methods such as the measurement of thiobarbituric acid reactive substances (TBARS). (Yagi, Chem. Phys. Lipids, 45: 337-351 (1987)).
One method for the measurement of general antioxidant capacity is stopped-flow kinetic analysis. (Mukai, et al., Bull. Chem. Soc. Jpn., 59: 3113-3116 (1986); Mukai, et al., J. Org. Chem., 54: 557-560 (1989); Mukai, et al. J. Org. Chem., 53: 430-432 (1988)). This is a sophisticated setup wherein, one measures radical transfer from a stable radical, (for example 2,6-di-tert-butyl-4-(4-methoxyphenyl)phenoxy), to a test compound spectrophotometrically as a function of time. Mukai et al. have demonstrated that a linear relationship exists between second-order rate constants derived from stopped-flow measurements and their half-peak oxidation potentials as measured voltammetrically. (Mukai, et al., Bull. Chem. Soc. Jpn., 59: 3113-3116 (1986); Mukai, et al., J. Org. Chem., 54: 557-560 (1989); Mukai, et al. J. Org. Chem., 53: 430-432 (1988)). Voltammetry has been used by Moldeus et al. to study the antioxidant capacity of structurally related dibenzo[1,4]dichalcogenines as inhibitors of lipid peroxidation. (Cotgreave, et al., Biochem. Pharm., 42: 1481-85 (1991)). In their case, a strong correlation between voltammetric potential and the ability to inhibit lipid peroxidation was observed.
As a secondary screen, test compounds are evaluated ex vivo for their oral effectiveness to inhibit LDL oxidation. In this assay, a better assessment of drug biodistribution into LDL particles is obtained. Again, the conjugated diene assay is used to assess lipid peroxidation.
Redox Potential and In Vitro LDL Oxidation
The general antioxidant capacity of several reference agents and the compounds of the present invention as measured by cyclic voltammetry is shown in Table III. A linear dependence of oxidation potentials to hydrogen atom donation capacity exists for compounds of similar structure. (Mukai, et al., J. Org. Chem., 53: 430-432 (1988); Mukai, et al., J. Org. Chem., 55: 552-556 (1989); Mukai, et al., J. Org. Chem., 56: 4188-4192(1991)). The lower the oxidation potential (voltage) the easier the compound is to oxidize. For the in vitro LDL oxidation assay, (Steinbrecher, et al., Proc. Natl. Acad. Sci. U.S.A., 81: 3883-3887 (1984)) test compounds were incubated (10 μM) with fresh plasma derived from rabbits maintained on a diet which enriches LDL in linoleate content; LDL was then isolated from the treated plasma, dialyzed, and incubated under oxidizing conditions (added Cu ++ ). Oxidation was measured spectrophotometrically by conjugated diene formation and the lag time extension versus control (ratio of treated/control) was determined from the first derivative of the A 234 kinetic curves.
TABLE III______________________________________Redox Potential and In Vitro LDL Oxidation Oxd. Potential LDL Oxd. Inhib.Compound Volts n mean lag ratio______________________________________Butylatedhydroxy- N.T. 1 1.38toluenePROBUCOL 1.12 28 1.38ETHOXYQUIN N.T. 1 1.21Ascorbate N.T. 1 1.00α-Tocopherol 0.81 5 1.01γ-Tocopherol N.T. 2 1.17γ-Tocotrienol 0.94 3 1.274 0.47 6 1.808 1.20 1 1.64______________________________________ N.T. = Not Tested
Ex Vivo LDL Antioxidant Effects of Standard Reference Agents and Compounds of the Present Invention
Hamsters (n=6 per group) were placed on an atherogenic diet (0.4% cholesterol+10% vitamin E stripped corn oil), and were orally dosed for 17 days with the indicated compounds at 75 mpk/day. The resistance of hamster LDL to copper-dependent oxidation in vitro was determined by conjugated dienes or lipid peroxides. (Esterbauer, et al., Free Rad. Res. Comms., 6: 67-75 (1989)). Table IV gives the lag phase extension values (lag ratio) estimated from the conjugated diene curves, and the rate of initial formation of lipid hydroperoxides during LDL oxidation by Cu ++ in vitro (given as % of control at the early incubation time points).
TABLE IV______________________________________Ex Vivo LDL Lipid Peroxidation Assay % of % ofCompound Conj. Dienes Control Control(mg/kg/d) lag ratio (a) 1.5 h (b) 3.0 h (b)______________________________________Probucol (50) 1.12 48 93α-Tocopherol >3 15 36(50)γ-Tocotrienol 1.48 7 67(50)Na Ascorbate 1.33 8 91(50)4(50) 1.57 3 31Ethoxyquin (75) 1.81 0 13______________________________________ (a) Measures the ability of the antioxidant to inhibit initiation of conjugated diene formation in LDL as a function of time, expressed as treated/control. (b) Measures the ability of the antioxidant to inhibit lipid peroxide formation in LDL at 1.5 hour and 3 hour time points.
The antioxidant effectiveness of ETHOXYQUIN and compound 4 have been examined in vitro and ex vivo [Tables III, IV]. In particular, compound 4 exhibits a lower oxidation potential and superior LDL protective capacity over standard reference agents.
The results to the above tests demonstrates that the compounds of Formula IV inhibit HMGR activity which results in a decrease in serum total cholesterol and LDL cholesterol levels, and inhibit the oxidation of LDL.
Thus, the compounds of Formula IV may be readily administered, to treat hypercholesterolemia, hyperlipidemia, and atherosclerosis, and to inhibit LDL oxidation in avian and mammalian systems in need of such treatment. For this purpose, the drug may be administered by conventional routes including, but not limited to, the alimentary canal in the form of oral doses, or by injection in sterile parenteral preparations.
In yet another aspect, the present invention provides a pharmaceutical composition which comprises a compound of Formula IV and a non-toxic pharmaceutically acceptable carrier. These carriers can be solid or liquid such as cornstarch, lactose, sucrose, olive oil or sesame oil. If a solid carrier is used, the dosage forms may be tablets, capsules, powders, troches or lozenges. If the liquid form is used, soft gelatin capsules, syrup or liquid suspensions, emulsions, or solutions in convenient dosage forms may be used. The composition may be made up of any pharmaceutical form appropriate for the desired route of administration. Examples of such compositions include solid compositions for oral administration such as tablets, capsules, pills, powders and granules, liquid compositions for oral administration such as solutions, suspensions, syrups or elixirs and preparations for parenteral administration such as sterile solutions, suspensions or emulsions. They may also be manufactured in the form of sterile solid compositions which can be dissolved in sterile water, physiologically saline or some other sterile injectable medium immediately before use.
The dosage ranges will commonly range from about 50 mg to about 200 mg. Optimal dosages and regimes for a given host can be readily ascertained by those skilled in the art. It will, of course, be appreciated that the actual dose used will vary according to the particular composition formulated, the particular compound used, the disease being treated. Many factors that modify the action of the drug will be taken into account including age, weight, sex, diet, time of administration, route of administration, rate of excretion, condition of the patient, drug combinations, reaction sensitivities and severity of the disease.
All publications cited in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. Each publication is individually incorporated herein by reference in the location where it is cited.
The following examples are intended for illustrative purpose only and are not to be construed as limiting the invention in sphere or scope.
Melting points were recorded on a Thomas-Hoover melting point apparatus and are uncorrected. Boiling points are uncorrected. Infrared spectra were obtained on a Perkin-Elmer Model 1800 FT-IR spectrophotometer. 1 H-NMR spectra were recorded on a Bruker AM 300 spectrometer or a Varian Gemini 300 NMR spectrometer; nuclear magnetic resonance (NMR) spectral characteristics refer to chemical shifts (δ) expressed in parts per million (ppm) with tetramethylsilane (TMS) as an internal standard. The relative area reported for the various shifts in the proton NMR spectral data corresponds to the number of hydrogen atoms of a particular functional type in the molecule. Mass spectra were measured on a Finnegan 4500 spectrometer (low resolution).
Thin-layer chromatography was performed on silica gel 60 F-254 plates purchased from E. Merck and company (visualization with iodine or phosphomolybdic acid); flash chromatography was performed on fine silica (EM Sciences, 230-240 mesh). All reactions were run under dry nitrogen unless otherwise indicated. Dry solvents were purchased from Aldrich, Milwaukee, Wisc. in sure/seal bottles and transferred by syringe under nitrogen. Most commercially available starting materials did not require further purification.
EXAMPLE 1
6-Hydroxy-1,2-Dihydro-2,2,4-Trimethylquinoline, (2)
6-Ethoxy-2,2,4-trimethyl-3,4-dihydroquinoline [Ethoxyquin (70 g, 0.32 mole)], was added to 250 mL of 48% HBr, and the mixture was heated to reflux for about 1 hour. The solution was cooled and poured into water. The aqueous suspension was made basic (pH=14) by the addition of 50% aqueous NaOH. Concentrated HCl was added to adjust the pH to about 4, then the mixture was made slightly basic by the addition of saturated sodium bicarbonate solution. The mixture was extracted with EtOAc and the organic layers were dried (brine, MgSO 4 ) and concentrated in vacuo. The thick dark oil was triturated with toluene and the insoluble residue was filtered. The crude solid was recrystallized from toluene to give the title compound as a light brown solid (mp 182°-184°, 34 g, 0.18 mole, 56%). An analytical sample was prepared by another recrystallization from toluene to provide light brown crystals, mp 182°-184°: IR (KBr) 3302, 2972, 2934, 1586, 1495, 1344, 1244, 1154, 880, 814 cm -1 ; 1 H NMR (D-6 DMSO) δ 1.12 (s, 6H), 1.33 (s, 3H), 3.34 (s, 1H), 5.17 (br s, 1H), 5.26 (s, 1H), 6.28-6.42 (m, 3H); MS m/e 190 (MH + ).
Anal. Calcd. for C 12 H 15 N 1 O 1 :
C, 76.16; H, 7.99; N, 7.40.
Found: C, 76.29; H, 7.95; N, 7.37.
EXAMPLE 2
1-Acetyl-6-Hydroxy-1,2-Dihydro-2,2,4-Trimethylquinoline, (3)
6-Hydroxy-1,2-dihydro-2,2,4-trimethylquinoline (12 g, 0.064 mole), and sodium acetate (10.4 g, 0.13 mole) were stirred in 75 mL of acetic anhydride at 100° for about 3 hours. The mixture was poured into water and extracted into ether. The ether extracts were combined and successively washed with water, aqueous NaHCO 3 , dried (brine, MgSO 4 ) and concentrated in vacuo. Purification of the crude material by flash chromatography [5:1 Hexanes:Et 2 O] yielded the diacetyl derivative as a dark yellow oil: 1 H NMR (CDCl 3 ) δ 1.48 (s, 6H), 1.95 (s, 3H), 2.12 (s, 3H), 2.27 (s, 3H), 5.51 (s, 1H), 6.76-6.90 (m, 3H).
The diacetyl derivative (12 g) was dissolved in 100 mL of ether. The ether solution was cooled to about -78° and 1M KOH/MeOH (20 mL) was added. The reaction mixture was stirred at -78° for about 1 hour at which time TLC indicated the reaction to be complete. The solution was poured into 1N HCl and extracted into ether. The ether extracts were dried (brine, MgSO 4 ) and concentrated in vacuo. The resulting solid was recrystallized from acetonitrile to give the title compound as an off white solid (mp 214°-216°, 5.9 g, 0.026 mole, 40%): IR (KBr) 3126, 2972, 1626, 1596, 1460, 1368, 1344, 1252, 1218, 868 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.20 (s, 6H), 1.70 (s, 3H), 1.80 (s, 3H), 5.23 (s, 1H), 6.34-6.44 (m, 3H), 8.61 (s, 1H); MS m/e 232 (MH + ).
Anal. Calcd. for C 14 H 17 N 1 O 2 :
C, 72.70; H, 7.41; N, 6.06.
Found: C, 72.89; H, 7.46; N, 6.09.
EXAMPLE 3
1-Acetyl-1,2-Dihydro-2,2,4-Trimethyl-6-[(5,9,13-Trimethyl-4(E),8(E),12-tetradecatrienyl)oxy]Quinoline, (Scheme I)
1-Acetyl-6-hydroxy-1,2-dihydro-2,2,4trimethylquinoline (4.0 g, 17.3 mmole), farnesyl ethanol 1b (4.3 g, 17.3 mmole), and triphenylphosphine (5.0 g, 19.0 mmole) were dissolved in 30 mL of THF. Diethylazodicarboxylate (3.3 g, 19.0 mmole) was added dropwise over 5 minutes, and the solution was stirred at about 23° for about 40 hours. The volatile components were removed in vacuo and the oily solid was triturated with ether. The solid was removed by filtration and the residue was purified by flash chromatography [gradient 6:1 to 5:1 Hexanes:Ether] to yield the title compound as a yellow oil (6.1 g, 13.2 mmole, 76%): IR (film) 2924, 1672, 1606, 1492, 1364, 1324, 1204 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.50 (s, 6H), 1.59 (s, 6H), 1.61 (s, 3H), 1.68 (s, 3H), 1.83 (m, 2H), 1.94-2.14 (m, 8H), 2.01 (s, 3H), 2.11 (s, 3H), 2.17 (m, 2H), 3.95 (t, J=6.4 Hz, 2H), 5.08-5.19 (m, 3H), 5.54 (s, 1H), 6.65-6.79 (m, 3H); MS m/e 464 (MH + ).
Anal. Calcd. for C 31 H 45 N 1 O 2 :
C, 80.30; H, 9.78; N, 3.02.
Found: C, 80.03; H, 9.70; N, 3.04.
EXAMPLE 4
1,2-Dihydro-2,2,4-Trimethyl-6-[(5,9,13-Trimethyl-4(E), 8(E), 12-tetradecatrienyl)oxy]Quinoline, (4) ##STR9##
1-Acetyl-1,2-dihydro-2,2,4-trimethyl-6-[(5,9,13-trimethyl-4(E), 8(E), 12-tetradecatrienyl) oxy]quinoline (8.2 g, 17.7 mmole) was dissolved in 75 mL of THF and the solution was cooled to about -10°. Lithium triethylborohydride (1.0M, 89 mL, 89 mmole) was added dropwise to the mixture end the cooling bath was removed. After stirring at about 23° for about 60 hours, the reaction was quenched by the careful addition of saturated NH4Cl solution. The mixture was poured into water and extracted into ether. The ether extracts were dried (brine, MgSO 4 ) and concentrated in vacuo. Purification of the crude material by flash chromatography [20:1 Hexanes:Et 2 O] yielded the dihydroquinoline as a yellow oil (6.2 g, 12. 8 mmole, 72%): IR (film) 3364, 2964, 1650, 1580, 1498, 1446, 1380, 1260, 1156 cm -1 ; 1 H NMR (CDCl 3 +TFA) δ 1.50 (s, 6H), 1.57 (s, 6H), 1.59 (s, 3H), 1.65 (s, 3H), 1.85 (m, 2H), 1.94-2.14 (m, 8H), 2.07 (s, 3H), 2.16 (m, 2H), 3.94 (t, J=6.3 Hz, 2H), 5.0 (m,3H), 5.63 (s, 1H), 6.76 (d of d, J=2.5, 8.6 Hz, 1H), 6.88 (d, J=2.5 Hz, 1H), 7.32 (d, J=8.6 Hz, 1H); MS m/e 422 (MH + ).
Anal. Calcd. for C 29 H 43 N 1 O 1 :
C, 82.61; H, 10.28; N, 3.32.
Found: C, 82.71; H, 10.40; N, 3.21.
EXAMPLE 5
O-[1,2-Dihydro-2,2,4-Trimethylguinoline]Dimethylthiocarbamate, (5)
6-Hydroxy-1,2-dihydro-2,2,4-trimethylquinoline (6 g, 31.7 mmole) and dimethylthiocarbamoyl chloride (5.2 g, 42.3 mmole) were dissolved in 50 mL of DMF. The mixture was cooled to about 0° and sodium hydride (1.3 g, 31.7 mmole, 60%) was added portionwise. The mixture was warmed to about 60° until complete by TLC (1 hour). The solution was poured into water and the solid was collected by filtration to yield the title compound as brown solid (mp 125-128, 8.0 g, 29 mmole, 92%). A portion of the material was recrystallized from toluene/hexanes for analysis (pale amber crystals, mp 128°-130°): IR (KBr) 3322,2962, 1536, 1496, 1482, 1394, 1288, 1254, 1194, 1154, 880, 814 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.25 (s, 6H), 1.92 (s, 3H), 3.29 (s, 3H), 3.43 (s, 3H), 5.29 (s, 1H), 6.37 (d, J=8.2 Hz, 1H), 6.65 (d of d, J=8.2,2.6 Hz, 1H), 6.70 (d, J=2.6 Hz, 1H); MS m/e 277 (MH + ).
Anal. Calcd. for C 15 H 20 N 2 O 1 S 1 :
C, 65.18; H, 7.29; N, 10.14.
Found: C, 65.53; H, 7.36; N, 9.82.
EXAMPLE 6
S-[1,2-Dihydro-2,2,4-Trimethylquinoline]Dimethylthiocarbamate, (Scheme II)
p-Toluenesulfonic acid monohydrate (550 mg, 2.9 mmole) was heated under vacuum (15 mm) for about 3 hours at about 150° to remove water. O-[1,2-Dihydro-2,2,4-trimethylquinoline] dimethylthiocarbamate 5 (4 g, 14.5 mmole) was added to the cooled acid, and the mixture was slowly heated under 15 mm of pressure to 180°-200° at which time the components became a homogeneous melt. The vessel was pressurized with nitrogen (1 atm). The mixture was then heated at about 207° for about 1 hour, at which time TLC indicated the conversion to be approximately 75% complete. The reaction mixture was cooled and dissolved into ethyl acetate. The solution was treated with activated carbon, filtered and concentrated in vacuo. Purification of the crude material by flash chromatography [gradient 4:1 to 2:1 Hexanes:Et 2 O] yielded the dihydroquinoline as an amber solid (2.4 g, 8.7 mmole, 60%). A sample was recrystallized from toluene/hexanes for analysis (pale amber crystals, mp 89°-90°): IR (KBr) 3332,2970, 1651, 1596, 1488, 1448, 1362, 1260, 1102, 1092, 828 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.27 (s, 6H), 1.96 (s, 3H), 3.04 (br s, 6H), 5.31 (s, 1H), 6.56 (d, J=1.7 Hz, 1H), 6.72 (d of d, J=9.0, 1.7 Hz, 1H), 6.7.03 (d, J=9.0 Hz, 1H); MS m/e 277 (MH + ).
Anal. Calcd. for C 15 H 20 N 2 O 1 S 1 :
C, 65.18; H, 7.29; N, 10.14.
Found: C, 65.33; H, 7.23; N, 10.04.
EXAMPLE 7
1-Acetyl-S-[1,2-Dihydro-2,2,4-Trimethylquinoline]
S-[1,2-Dihydro-2,2,4-trimethylquinoline] dimethylthiocarbamate (6.5 g, 23.6 mmole) and sodium acetate (3.9 g, 47.1 mmole) were stirred in 50 mL of acetic anhydride at reflux for about 3 hours. The mixture was slowly poured into excess saturated NaHCO 3 solution (caution!). The mixture was extracted into ethyl acetate, and the organic layers were dried (brine, MgSO 4 ) and concentrated in vacuo. Purification of the crude solid by recrystallization from toluene/hexanes provided the N-acetyl derivative as a pale amber solid, mp 110°-112° (2.2 g, 6.9 mmole, 29%): IR (KBr) 2960, 1683, 1651, 1552, 1492, 1474, 1366, 1314, 1242, 1098, 840 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.48 (s, 6H), 1.97 (s, 3H), 2.18 (s, 3H), 2.99 (br s, 6H), 5.49 (s, 1H), 6.92 (d, J=1.2 Hz, 1H), 7.16 (m, 2H); MS m/e 319 (MH + ).
Anal. Calcd. for C 17 H 22 N 2 O 2 S 1 :
C, 64 . 12; H, 6.96; N, 8.80.
Found: C, 64.19; H, 6.82; N, 8.76.
EXAMPLE 8
1-Acetyl-1,2-Dihydro-2,2,4-Trimethylguinoline-6-Thiol, (7)
1-Acetyl-S-[1,2-dihydro-2,2,4-trimethylquinoline]dissolved in a solution of sodium methoxide prepared from sodium (360 mg, 15.7 mmole) in methanol (20 mL). The mixture was stirred for about 48 hours at about 23° at which time TLC indicated complete hydrolysis. The mixture was poured into 1N HCl and extracted into ether. The ether extracts were combined, dried (brine, MgSO 4 ) and concentrated in vacuo. Purification of the crude material by flash chromatography [gradient 5:1 to 4:1 Hexanes:Et 2 O] yielded the free thiophenol as a yellow oil (1.4 g, 5.7 mmole, 72%): 1 H NMR (CDCl 3 ) δ 1.48 (s, 6H), 1.96 (s, 3H), 2.16 (s, 3H), 5.45 (s, 1H), 6.73 (d, J=1.2 Hz, 1H), 6.98 (d of d, J=1.2, 9.0 Hz, 1H), 7.06 (d, J=9.0 Hz, 1H), MS m/e 248 (MH + ).
EXAMPLE 9
1-Acetyl-1,2-Dihydro-2,2,4-Trimethyl-6-[(5,9,13-Trimethyl-4(E),8(E),12tetradecatrienyl)thio]
1-Acetyl-1,2-dihydro-2,2,4-trimethylquinoline-6thiol (1.4 g, 5.67 mmole), potassium carbonate (1.2 g, 8.5 mmole), and farnesylethyl iodide (2.0 g, 5.67 mmole) were added to 30 mL of acetonitrile. TLC indicated the reaction to be complete after stirring for about 30 minutes at about 23°. The mixture was poured into water and extracted into ether. The ether extracts were combined, dried (brine, MgSO 4 ) and concentrated in vacuo. Purification of the crude material by flash chromatography [15:1 Hexanes:Et 2 O]yielded the title compound as a yellow oil (2.2 g, 4.59 mmole, 81%). A small sample was distilled in a Kugelrohr oven (bath 180°-190°/0.15 mm) for analysis: IR (film) 2924, 1680, 1594, 1492, 1362, 1314 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.48 (s, 6H), 1.56 (s, 6H), 1.58 (s, 3H), 1.64 (s, 3H), 1.65 (m, 2H), 1.90-2.15 (m, 10H), 1.98 (s, 3H), 2.14 (s, 3H), 2.86 (t, J=7.1 Hz, 2H), 5.07 (m,3H), 5.45 (s, 1H), 6.75 (d, J=1.7 Hz, 1H), 7.02 (d of d, J=1.7, 11 Hz, 1H), 7.06 (d, J=11.0 Hz, 1H); MS m/e 480 (MH + ).
Anal. Calcd. for C 31 H 45 N 1 O 1 S 1 :
C, 77.61; H, 9.45; N, 2.92.
Found: C, 77.31; H, 9.38; N, 2.88.
EXAMPLE 10
1,2-Dihydro-2,2,4-Trimethyl-6-[(5,9,13-Trimethyl-4(E),8(E),1 2-tetradecatrienyl)thio]Quinoline, (8) ##STR10##
1-Acetyl-1,2-dihydro-2,2,4-trimethyl-6-[(5,9,13-trimethyl-4 (E), 8 (E), 12-tetradecatrienyl)thio]quinoline (1.9 g, 3.97 mmole) was dissolved in 20 mL of THF and the solution was cooled to about -10°. Lithium triethylborohydride (1.0M, 19.8 mL, 19.8 mmole) was added dropwise to the mixture and the cooling bath was removed. After stirring at about 23° for about 15 hours, the reaction was quenched by the careful addition of saturated NH 4 Cl solution. The mixture was poured into water and extracted into ether. The ether extracts were dried (brine, MgSO 4 ) and concentrated in vacuo. Purification of the crude material by flash chromatography [20:1 Hexanes:Et 2 O]yielded the dihydroquinoline as a yellow oil (1.3 g, 2.97 mmole, 75%): IR (film) 3372,2964, 1652, 1598, 1448, 1258, 1168 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.26 (s, 6H), 1.59 (s, 9H), 1.65 (m, 2H), 1.67 (s, 3H), 1.95 (s, 3H), 1.95-2.15 (m, 10H), 2.16 (m, 2H), 2.86 (t, J=7.2 Hz, 2H), 3.72 (br s, 1H), 5.08 (m,3H), 5.26 (s, 1H), 6.40 (d, J=1.8 Hz, 1H), 6.57 (d of d, J=8.0, 1.8 Hz, 1H), 6.94 (d, J=8.0 Hz, 1H); MS m/e 438 (MH + ).
Anal. Calcd. for C 29 H 43 N 1 S 1 :
C, 79.57; H, 9.90; N, 3.20.
Found: C, 79.61; H, 9.61; N, 3.24.
EXAMPLE 11
4-Methyl-1-[[[4-Nitrophenyl]methyl]sulfonyl]benzene, (Scheme III)
4-Nitrobenzyl chloride (5.0 g, 29.1 mmole) and sodium p-toluenesulfinate (6.8 g, 37.9 mmole) were dissolved in 50 mL of dry DMF. The mixture was stirred at about 23° for about 18 hours then diluted with water. The sulfone crystallized from the aqueous mixture and was filtered. The sulfone was purified by recrystallization from ethanol to give a pale yellow crystalline solid, mp 188°-190° (7.6 g, 25.9 mmole, 89%): IR (KBr) 2994, 1598, 1514, 1490, 1342, 1312, 1304, 1148, 824 cm -1 ; 1 H NMR (CDCl 3 ) δ 2.44 (s, 3H), 4.38 (s, 2H), 7.27 (m, 4H), 7.53 (d, J=8.3 Hz, 2H), 8.13 (d, J=8.3 Hz, 2H); MS m/e 292 (MH + ).
Anal. Calcd. for C 14 H 13 N 1 O 4 S 1 :
C, 57.72; H, 4.50; N, 4.81.
Found: C, 57.72; H, 4.46; N, 4.80.
EXAMPLE 12
4-[[[(4-Methylphenyl)sulfonyl]methyl]Aniline, (9)
A solution of 4-methyl-1-[[[4-nitrophenyl]methyl]sulfonyl] benzene (15 g, 51 mmol) in ethanol (250 mL) containing stannous chloride dihydrate (57.5 g, 255 mmol) was heated to reflux for about 3 hours. The mixture was cooled, poured into water and neutralized with 20% aqueous sodium hydroxide. The solution was filtered and dried under aspirator vacuum. The pale yellow solid was washed with hot ethyl acetate (3 L) and the solvent removed in vacuo to give 3 as white needles (13.4 g, 5.1 mmole, 75%) mp 217°-218°: IR (KBr) 3444, 3370, 1636, 1612, 1294, 1284, 1142 cm -1 ; 1 H NMR (CDCl 3 ) δ 2.40 (s, 3H), 3.70 (s, exchanges with D 2 O, 2H), 4.16 (s, 2H), 6.54 (d, J=8.5 Hz, 2H), 6.83 (d, J=8.5 Hz, 2H), 7.22 (d, J=6.4 Hz, 2H), 7.50 (d, J=6.4,2H); MS m/e 261 (M + ).
Anal. Calcd. for C 14 H 15 N 1 O 2 S 1 :
C, 64.34; H, 5.78; N, 5.36.
Found: C, 64.50; H, 5.79; N, 5.32.
EXAMPLE 13
1,2-Dihydro-2,2,4-Trimethyl-6-[1-(4Methylphenyl)sulfonyl]Quinoline, (10)
A solution of 4-[[(4methylphenyl)sulfonyl]methyl] aniline (3.1 g, 10.6 mmol) in dioxane (150 mL) containing I 2 (160 mg, 0.6 mmol) was heated to about 90° C. and acetone(250 mL) was added dropwise such that a distillation rate of 1-2 drops/sec is maintained. After about 6 hours, acetone (100 mL) was added and the reaction mixture was refluxed overnight. The above sequence was repeated over a 12 hour period. The reaction mixture was cooled, concentrated and the black viscous oil was purified by flash chromatography with 30% ethyl acetate in hexanes as eluant to give the title compound as a pale yellow solid (2.17 g , 6.4 mmole, 52%) which can be further purified by recrystallization from ethyl acetate-ether to give a white solid mp 134°-135°: IR (KBr) 3380, 1375, 1300, 1140, 815 cm - ; 1 H NMR (CDCl 3 ) δ 1.24 (s, 6H), 1.77 (s, 3H), 2.39 (s, 3H), 3.77 (s, exchanges with D 2 O, 1H), 4.13 (s, 2H), 5.26 (s, 1H), 6.30 (d, J=8.0 Hz, 1H) 6.57 (s, 1H), 6.69 (dd, J=1.8, 6.3 Hz, 1H), 7.23 (d, J=8.3 Hz, 2H), 7.52 (d, J=8.3 Hz, 2H); MS m/e 341 (M + ).
Anal. Calcd for C 20 H 23 N 1 O 2 S 1 :
C, 70.35; H, 6.79; N, 4.10.
Found: C, 70.37; H, 6.81; N, 4.04.
EXAMPLE 14
N-Acetyl-1,2-Dihydro-2,2,4-Trimethyl-6-[1-(4methylphenyl)sulfonyl]Quinoline, (Scheme III)
A solution of 1,2-dihydro-2,2,4-trimethyl-6-[1(4-methylphenyl)sulfonyl]quinoline (3.4 g, 10 mmol) in acetic anhydride (9.6 mL, 100 mmol) containing sodium acetate (0.9 g, 11 mmol) was heated to reflux for about 1 hour, then stirred overnight at about 23°. The reaction is not complete as indicated by TLC analysis. Additional acetic anhydride (5 mL) was added and the mixture was heated to reflux for about 2 hours then cooled. The reaction mixture was poured into dilute sodium hydroxide (10%) and the aqueous layer extracted with ether. The ether extracts were dried (brine, MgSO 4 ) and concentrated in vacuo. The residue was purified by flash chromatography using 50% ethyl acetate in hexanes as an eluant to give N-acetyl derivative (3.19 g, 8.3 mmole, 83%) as a yellow oil: IR (film) 3018,2972,2926, 1675, 1315, 1150, 825 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.48 (s,6H), 1.86 (s, 3H), 2.11 (s, 3H), 2.40 (s, 3H), 4.24 (s, 2H), 5.48(s, 1H), 6.70-6.67(m, 1H), 6.85-6.81(m, 2H), 7.49(d, J=8.4 Hz, 2H), 7.51(d, J=8.4 Hz, 2H); MS m/e 383 (M + ).
EXAMPLE 15
N-Acetyl-1,2-Dihydro-2,2,4-Trimethyl-6-[1-f(4-Methylphenyl) sulfonyl)-6,10,14-Trimethyl-5 (E), 9 (E), 13Pentadecatrienyl] Quinoline, (Scheme III)
A solution of N-acetyl-1,2-dihydro-2,2,4-trimethyl-6-[1-(4-methylphenyl)sulfonyl]quinoline (7.89 g, 23.1 mmol) in THF (100 mL) was cooled to -78°, and treated with potassium bis(trimethylsilyl)amide (46.2 mmol, 23.1 mmol, 0.5 M in toluene) and stirred for about 15 minutes. DMPU (26 mL) was added to the reaction mixture followed by a solution of farnesylethyl iodide (8.2 g, 23.1 mmol) in THF (25 mL). The reaction mixture was stirred for about 1 hour at about -78° then poured into water (100 mL), and the aqueous layer was extracted with ether. The organic extracts were combined, dried (brine, MgSO 4 ) and concentrated in vacuo. The residue was purified by flash chromatography using 20% ethyl acetate in hexanes as an eluant to give the alkylated sulfone as a yellow oil (8.13 g, 13.2 mmole, 57%): IR (film) 2926, 1675, 1320, 1150, 820 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.34-1.22 (m, 4H), 1.48 (s, 6H), 1.52 (s, 3H), 1.55 (s, 3H), 1.57 (s, 3H), 1.68 (s, 3H), 1.81 (s, 3H), 1.93-2.10 (m, 10H), 2.10 (s, 3H), 2.35 (s, 3H), 3.98 (dd, J=3.9, 11.5 Hz, 1H), 4.98-5.07 (m, 3H), 5.47 (s, 1H), 6.92 (d, J=8.2 Hz, 1H), 7.02-7.05 (m, 2H), 7.14 (d J=8.11 Hz, 2H), 7.38 (d, J =8.1 Hz, 2H); MS m/e 615 (M + ).
Anal. Calcd for C 39 H 53 N 1 O 3 S 1 :
C, 76.05; H, 8.67; N, 2.28.
Found: C, 76.15; H, 8.68; N, 2.30.
EXAMPLE 16
N-Acetyl-1,2-Dihydro-2,2,4-Trimethyl-6-[6,10,14-Trimethyl-5(E),9(E),13-Pentadecatrienyl]Quinoline, (Scheme III)
A mixture of N-acetyl-1,2-dihydro-2,2,4-trimethyl-6-[1-((4-methylphenyl)sulfonyl)-6,10,14-trimethyl-5 (E), 9(E), 13-pentadecatrienyl]quinoline (8.1 g, 13.2 mmol) and disodium hydrogen phosphate (7.5 g, 53 mmol) in methanol (50 mL) were cooled to about 0°. Sodium amalgam (10 mesh, 6% Na, 18.6 g) was added, and after about 30 minutes, the reaction mixture was warmed to 23° C. and stirred for an additional 12 hours. The reaction mixture was poured into water (50 mL) and the aqueous layer extracted with ether. The ether extracts were combined, dried (brine, MgSO 4 ) and concentrated in vacuo. The residue was purified by flash chromatography [gradient 10:1 to 5:1 Hexanes:EtOAc] to give the N-acetyl derivative as a clear oil (3.48 g, 7.5 mmole, 57%): IR (film) 2965-2854, 1678, 1450, 823 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.28-1.41 (m, 2H), 1.44 (s, 6H), 1.53 (s, 12H), 1.61 (s, 3H), 1.84-1.97 (m, 12H), 2.08 (s, 3H), 2.54 (t, J=7.6 Hz, 2H), 4.99-5.09 (m, 3H), 5.43 (s, 1H), 6.69 (d, J=8.0 Hz, 1H), 6.92 (d, J=8.0 Hz, 1H) 6.94 (s, 1H); MS m/e 461 (M + ).
Anal. Calcd for C 32 H 47 N 1 O 1 :
C, 83.24; H, 10.26; N, 3.03.
Found: C, 83.64; H, 10.40; N, 3.05.
EXAMPLE 17
1,2-Dihydro-2,2,4-Trimethyl-6-[6,10,14-Trimethyl5(E),9(E), 13-Pentadecatrienyl]Quinoline, (11) ##STR11##
Lithium triethylborohydride (22.7 mL, 22.7 mmol, 1.0 M in THF) was added to a solution of the acetamide (3.48 g, 7.56 mmol) maintained at about 0° in THF (50 mL). The reaction was slowly warmed to about 23° and stirred for about 12 hours. The reaction mixture was poured into water (100 mL) and the aqueous layer extracted with ethyl acetate. The organic extracts were combined, dried (brine, MgSO 4 ) and concentrated in vacuo. The residue was purified by flash chromatography [20:1 Hexanes: EtOAc] to give in order of elution: Compound of example (11)(1.28 g, 3.1 mmole, 40%) and the starting material (1.42 g, 3.1 mmole, 41%): IR (film) 3380,2900, 1450, 1380, 810 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.25 (s, 6H), 1 17-1 42 (m, 4 H), 1.42-1.59 (m, 12H), 1.68 (s, 3H), 1.98 (s, 6 H), 1.96-2.04 (m, 4 H), 2.34 (m, J=7.2 Hz, 2H), 3.54 (br s, exchanges with D 2 0, 1H), 5.07-5.12 (m, 3H), 5.29 (s, 1H), 6.36 (d, J=7.8 Hz, 1H), 6.86 (d, J=7.9 Hz, 1H), 6.86 (s, 1H); MS m/e 419 (M + ).
Anal. Calcd for C 30 H 45 N 1 :
C, 85.86; H, 10.81; N, 3.34.
Found: C, 85.87; H, 10.82; N, 3.23.
EXAMPLE 18
[4-(1,1-dimethylethyl)dimethylsilyloxy]butana], C12) and ethyl 2-methyl-6-[(1,1-dimethylethyl)dimethylsilyloxy]-2(E)-hexenoate, (13)
To a solution of 5-methyl-4-hexenal (Marbet, et al., Helv. Chim. Acta., 50: 2095-3000 (1967)) (18.8 g, 168 mmol) in ethanol (100 mL) at 0° is added dropwise a solution of sodium borohydride (1.7 g, 46.2 mmol) in methanol (100 mL). The reduction is complete in about 30 minutes as indicated by TLC analysis. The reaction mixture is neutralized with diluted aqueous acetic acid (10%), then poured into water and the aqueous layer extracted with ether. The ether extracts are washed with water, dried (brine, MgSO 4 ) and concentrated to give the alcohol (13.89 g, 122 mmol, 57%) as a clear oil (bp 108°-120°/0.25 mm Hg).
A solution of alcohol (13.9 g, 122 mmol) in DMF (100 mL), tert-butyldimethylsilyl chloride (20.1g, 134 mmol) and imidazole (9.95g, 146 mmol) is stirred at about 23° for about 24 hour. The reaction mixture is poured into water and the aqueous layer extracted with ether. The ether extracts are washed with water, dried (brine, MgSO 4 ) and concentrated. The residue is purified by flash chromatography using hexanes as eluant to give the silyl ether (17.9 g, 64%, 78.5 mmol) as a clear oil (bp 57°-60° C./0.25 mmHg): IR(film) 2956,2930,2888, 1380, 1250, 1100, 840 cm -1 ; 1 H NMR(CDCl 3 ) δ 0.042 (s, 6H), 0.89 (s, 9H), 1.54 (d of t, J=8.17, 7.0 Hz,2H), 1.59 (s, 3H), 1.67 (s, 3H), 2.02 (dd, J=7.3, 14.8 Hz, 2H), 3.59 (t, J=6.5 Hz, 2H), 5.11 (t, J=7.2 Hz, 1H); MS 228 (M + ).
Anal. Calcd. for C 13 H 28 OSi:
C, 68.35; H, 12.35.
Found: C, 68.66; H, 12.50.
A solution of the silyloxyolefin (2.0 g, 8.8 mmol) in dichloromethane (50 mL) is cooled to about -78° and ozone is bubbled through the solution until a light blue color remains. The ozone flow is turned off and nitrogen is bubbled through the solution until the ozone color fades. Dimethyl sulfide (1.9 mL, 36.4 mmol) is added and the mixture stirred at about -78° for about 1 hour and at about 23° for about 2 hours. (Note: The aldehyde 12 decomposed during an attempted distillation thus the aldehyde was not isolated.) To the reaction mixture is added (carbethoxyethylidene) triphenylphosphorane (3.3 g, 8.8 mmol) and the yellow solution is stirred for about 2 hours. Although the yellow color of the phosphorane is gone after about 2 hours, TLC analysis indicates some aldehyde remains. Additional phosphorane (0.5 g, 1.4 mmol) is added and the reaction mixture is stirred for about 48 hours at about 23°. The reaction mixture is concentrated, triturated with pentane, filtered, concentrated and the residue purified by flash chromatography to give 13 (2.3295 g, 93%, 8 1 mmol) as a clear oil: IR (film) 1710, 1370, 1260, 1100, 840 cm -1 ; 1 H NMR (CDCl 3 ) δ 0.023 (s, 6H), 0.87 (s, 9H), 1.26 (t, J=7.1 Hz, 3H), 1.62(dt, J=14.6, 6.2 Hz, 2H), 1.80 (s, 3H), 2.22 (q, J=7.4, 14.9 Hz, 2H), 3.60 (t, J=6.2 Hz, 2H), 4.15 (q, J=7.1, 14.2 Hz, 2H), 6.74 (t, J=7.5 Hz, 1H); MS 286 (M + ).
Anal. Calcd. for C 15 H 30 O 3 Si
C, 62.89; H, 10.56.
Found: C, 62.88; H, 10.65.
EXAMPLE 19
2-Methyl-6-[(1,1-dimethylethyl) dimethylsilyloxy]-2(E)-hexenol, (14)
Diisobutylaluminum hydride (42 mL, 42 mmol, 1.0 M in toluene) in THF (50 mL) is added to a solution of ester 13 (6.0 g, 21.0 mmol) in THF (50 mL) at about -78° and stirred for about 4 hours. A solution of NaOH (1N, 100 mL) is added and the aqueous layer extracted with ether. The ether extracts are combined, washed with saturated aqueous sodium chloride, dried over magnesium sulfate and concentrated. The oily residue is purified by flash chromatography to give in order of elution (0.12 g, 0.49 mmol, 2%) of the Z isomer and 14 (3.677 g, 15.1 mmol, 72%) of a mixture of E and Z isomers (E/Z=30.6/1): IR(film) 3335,2900, 1450, 1390, 1360, 1250, 1100, 1060, 840 cm -1 ; 1 H NMR (CDCl 3 ) δ 0.014 (s, 6H), 0.85 (s, 9H), 1.21 (s, 1H, exchanges with D 2 O), 1.53 (dt, J=14.9, 6.4 Hz, 2H), 1.62 (s, 3H), 2.04 (dd, J =7.1, 14.8 Hz, 2H), 3.56 (t, J=6.4 Hz, 2H), 3.95 (s, 2H), 5.37 (tq, J=1.4, 7.3 Hz, 1H); MS m/e 244 (M + ).
Anal. Calcd. for C 13 H 20 O 2 Si
C, 63 . 88; H, 11.55.
Found: C, 64.00; H, 11.54.
EXAMPLE 20
6-Chloro-1-[(1,1-dimethylethyl)dimethylsilyloxy]-5-methyl-4(E)-hexene, (15)
N-chlorosuccinimide (2.5 g, 18.7 mmol) is dissolved in dichloromethane (100 mL), cooled to about 0° and treated with dimethyl sulfide (1.4 mL, 19.5 mmol) and stirred for about 1 hour. The alcohol (3.3 g, 13.5 mmol) is added and the reaction mixture stirred for about 3 hours. The solvent is removed in vacuo and the residue purified by flash chromatography with 10% ethyl acetate in hexanes as eluant. The chloride 15 is isolated as a clear oil (2.9 g, 11.1 mmol, 82%).
EXAMPLE 21
General Procedure for the Synthesis of Benzyl Sulfones
The commercially available benzyl bromide or benzyl chloride (50 mmole) and sodium p-toluenesulfinate (65 mmole) were dissolved in 50-100 mL of dry DMF. The mixtures were stirred at about 23° for about 18 hours then diluted with water. In most cases the sulfones crystallized from the aqueous mixture and were filtered, if not, they were extracted into ether. The compounds were purified by recrystallization (EtOH) or column chromatography.
4-Methyl-1-[[[3-(trifluoromethyl) phenyl]methyl]sulfonyl]benzene
Colorless plates, mp 139°-140°: IR (KBr) 2954, 1614, 1598, 1450, 1332, 1312, 1288, 1164, 1142, 1116, 1074 cm -1 ; 1 H NMR (CDCl 3 ) δ 2.44 (s, 3H), 4.34 (s, 2H), 7.16 (s, 1H), 7.26 (d, J=8.1 Hz, 2H), 7.42 (m, 1H), 7.50 (d, J=8.1 Hz, 2H), 7.58 (d, J=7.5 Hz, 1H); MS m/e 315 (MH + ).
Anal. Calcd. for C 15 H 13 F 3 O 2 S 1 :
C, 57.32; H, 4.17.
Found: C, 57.28; H, 4.08.
EXAMPLE 22
7-[(1,1-Dimethylethyl)dimethylsilyloxy]-3-Methyl-1-[(4-Methylphenyl) sulfonyl]-1-[3(Trifluoromethyl)phenyl]-hept-3(E)-ene , (16)
4-Methyl-1-[[[3-(trifluoromethyl)phenyl]methyl]sulfonyl]benzene (2.8 g, 8.9 mmol) in THF (20 mL) is cooled to about -78°, treated with nBuLi (8.9 mL, 8.95 mmol) and stirred for about 1 hour. Dry DMPU (5 mL) is added followed by a solution of the allylic chloride 15 (1.96 g, 7.48 mmol) in THF (10 mL). The mixture is warmed to about 0° and stored for about 48 hours. The reaction is poured into water (50 mL) and extracted with ether. The ether extracts are dried (MgSO 4 ) and concentrated. The residue is purified by flash chromatography with 10% ethyl acetate in hexanes as eluant to give 16 (2.60 g, 4.81 mmol, 65%) as a white solid (mp 80°-85°): IR (KBr) 1330, 1300, 1160, 1140, 1125, 1100, 840, 775 cm -1 ; 1 H NMR (CDCl 3 ) δ 0.06 (s, 6H), 0.80 (s, 9H), 1.14-1.31 (m, 2H), 1.44 (s, 3H), 1.80 (dd, J=14.6, 7.3 Hz, 2H), 2.35 (s, 3H), 2.78 (dd, J=12.2, 13.8 Hz, 1H), 3.05 (d, J=13.9 Hz, 1H), 3.10-3.31 (m, 2H), 4.22 (dd, J=3.7, 12.1 Hz, 1H), 5.02 (t, J=7.2 Hz, 1H), 7.09-7.16 (m, 3H), 7.35-7.37 (m, 4H) 7.46-7.48 (m, 1H); MS 540 m/e (M + ).
Anal. Calcd. for C 28 H 39 O 3 SF 3
C, 62.19; H, 7.27.
Found: C, 62.13; H, 7.22.
EXAMPLE 23
3-[3-Methyl-7-iodo-3(E)-hexenyl]-1-trifluoromethyl benzene, (17)
To a solution of sulfone 16 (2.6 g, 4.8 mmol) at 0° in methanol (50 mL) containing Na 2 HPO 4 (2.67 g, 18.8 mmoL) is added sodium amalgam (6% sodium). The reaction mixture is warmed to about 23° and stirred for about 4 hours then poured into water and the aqueous layer extracted with ether. The organic extracts are dried (brine, MgSO 4 ) and concentrated. The remaining clear oil is purified by column chromatography with 10% ethyl acetate in hexanes as eluant to give in order of elution the desulfonylated material (1.40 g, 3.63 mmol, 76%) as a clear oil and unreacted starting material 16 (0.47 g, 0.87 mmol, 18%).
The silyl ether (3.5 g, 9.1 mmol) is dissolved in THF (20 mL) and treated with tetrabutylammonium fluoride (15 mL, 15.0 mmol, 1.0 M in THF) and stirred at about 23° for about 1 hour. The reaction mixture is poured into water and the aqueous layer is extracted with ether. The ether extracts are combined, dried over magnesium sulfate and concentrated. The remaining clear oil can be purified by flash chromatography with 15% ethyl acetate in hexanes as eluant followed by 20% ethyl acetate in hexanes to give the alcohol (1.6 g, 5.88 mmol, 73%) as a clear oil: IR(film) 3340, 1450, 1325, 1160, 1125, 1075, 795 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.23 (t, J=5.0 Hz, 1H, exchanges with D 2 O), 1.54 (dt, J=14.4, 7.1 Hz, 2H); 1.64(s, 3H), 2.03 (dd, J=7.2, 14.6 Hz, 2H), 2.27 (t, J=8.3 Hz, 1H), 2.74 (t, J=7.8 Hz, 2H), 3.54 (m, 2H), 5.08 (t, J=7.2 Hz, 1H), 7.30-7.42 (m, 2H); MS 272 m/e (M + ).
Anal. Calcd. for C 15 H 19 OF 3 C, 66.16; H, 7.03.
Found: C, 66.12; H, 6.99.
A solution of the alcohol (2.0 g, 7.35 mmol) in dichloromethane (10 mL) at 0° is treated with triethylamine (1.03 ml, 8.1 mmol) then methanesulfonyl chloride (0.59 mL, 7.72 mmol). The reaction mixture is warmed to about 23° and stirred for about 12 hours. The reaction mixture is poured into water and the aqueous layer extracted with dichloromethane. The dichloromethane extracts are dried over magnesium sulfate and concentrated to give the mesylate (2.24 g, 87%, 6.4 mmol) as a clear oil. The oil is dissolved in acetone, NaI (11.0 g, 73.5 mmol) is added and the reaction mixture is heated to reflux for about 2 hours. The mixture is cooled, poured into water and the aqueous layer extracted with ether. The organic extracts are dried (MgSO 4 ) and concentrated to give the iodide 17 (2.24 g, 5.86 mmol, 80%) as a dark red oil.
EXAMPLE 24
1,2-dihydro-2,2,4-trimethyl-6-[[5-methyl-7-[3(trifluoromethyl) phenyl]-4(E)-hexenyl]oxy]quinoline, (18) ##STR12##
A mixture of phenol 3 (1.2 g, 5.2 mmol), iodide 17 (2.24 g, 5.86 mmol) and K 2 CO 3 (4.0 g, 29.3 mmoL) in DMF (20 mL) is stirred at about 23° for about 1 hour then at about 50° for about 12 hours and at about 90° for about 1 hour. The reaction mixture is cooled, poured into water and the aqueous layer extracted with ethyl acetate. The ethyl acetate extracts are dried over magnesium sulfate and concentrated. The resulting yellow oil is chromatographed to give the Nacetyl derivative (1.72 g, 60%, 3.59 mmol) as a yellow oil contaminated with 0.45 g of an unknown oil that does not interfere with the next reaction: IR (film) 1710, 1670, 1360, 1325, 1200, 1160, 1125, 850 cm -1 ; NMR (CDCl 3 ) δ 1.48 (s, 6H), 1.64 (s, 3H), 1.75 (dt, J =6.9, 13.6 Hz, 2H), 1.98 (s, 3H), 2.10 (s, 3H), 2.13 (q, J=7.6, 14.8 Hz, 2H), 2.28 (t, J=7.8 Hz, 2H), 2.75 (t, J=7.4 Hz, 2H), 3.85 (t, J=6.3 Hz, 2H), 5.52 (t, J=7.1 Hz, 1H), 6.63 (dd, J=2.8, 8.6 Hz, 1H), 6.73-6.77 (m, 2H), 7.29-7.41 (m, 4H); MS 485 m/e (M + ).
A solution of the acetamide (1.8 g, 3.7 mmol) in THF (40 mL) maintained at about -78° is treated with LiEt 3 BH (11.1 mL, 11.1 mmol, 1.0M in THF). The reaction is warmed to about 23° stirred for about 12 hours then poured into water (100 mL) and the aqueous solution extracted with ether. The ether extracts are dried (MgSO 4 ) and concentrated. The yellow residue is purified by column chromatography using 15% ethyl acetate in hexanes as eluant. The free amine is isolated as a light yellow oil (0.4519 g, 1.02 mmol, 28%) and 0.4522 g of an impurity from the previous reaction. Unreduced acetamide (0.817 g, 1.68 mmol, 45%) is also obtained. This procedure is repeated on the acetamide to give (0.105 g, 0.2 mmol, 6%) of unreacted starting material and additional free amine (0.245 g, 0.056 mmol, 14%): IR(film) 3360, 1380, 1325, 1260, 1160, 1125 cm -1 ; 1 H NMR (CDCl 3 ) δ 1.23 (s, 6H), 1.64 (s, 3H), 1.71 (dt, J=6.8, 13.8 Hz, 2H), 1.95 (br s, 3H), 2.11(q, J=7.3 , 14.5 Hz, 2H), 2.27(t, J=7.4,2H), 2.74 (t, 7.4 Hz, 2H), 3.81 (br s, 2H), 5.12 (t, J=7.2 Hz, 1H), 5.4 (br s, 1H), 6.39 (br s, 1H), 6.56 (dd, J=2.5, 8.3 Hz, 1H), 6.66 (br s, 1H), 7.32-7.39 (m, 4H)-(DMSO-d 6 ) δ 1.13 (s, 6H), 1.55-1.60 (m, 2H), 1.59 (s, 3H), 1.84 (s, 3H), 2.04 (dd, J=6.4, 14.5 Hz, 2H), 2.24 (t, J=7.9 Hz, 2H), 2.75 (t, J=7.6 Hz, 2H), 3.70 (t, J=6.3 Hz, 2H), 5.08 (t, J=6.4 Hz, 1H), 5.28 (s, 1H), 5.37 (s, 1H, exchanges with D 20 ), 6.36 (d, J=8.1 Hz, 1H), 6.47-6.50 (m, 2H), 7.47-7.51 (m, 4H); MS 443 m/e (M + ).
Anal. Calcd. for C 27 H 32 NOF 3
C, 73.11; H, 7.27; N, 3.16.
Found: C, 73.15; H, 7.35; N, 3.14.
Other embodiments of the invention will be apparent to the skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as examplary only, with the true scope and spirit of the invention being indicated by the following claims.
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The present invention relates to novel dihydroquinolines which are useful for cholesterol lowering and as antioxidant agents. Also provided is a process for preparing the dihydroquinolines of the present invention, pharmaceutical compositions, and a method of treating or inhibiting hypercholesterolemia, hyperlipidemia, atherosclerosis, and LDL oxidation which comprises administering to birds and mammals in need of such treatment an effective amount of a compound of the present invention.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to integrating heat recovery steam generation (HRSG) systems with gas turbine exhaust components, and more specifically, to a turbine exhaust gas plenum designed to promote uniform flow of combustion gases into the HRSG.
[0002] In combined cycle power generation systems, heated exhaust gas discharged from gas turbines may be used by HRSG systems as a source of heat which may be transferred to a water source to generate superheated steam. In turn, the superheated steam may be used within steam turbines as a source of power. The heated exhaust gas from a gas turbine may be delivered to the HRSG system through, among other things, an exhaust plenum and diffuser, which may help convert the kinetic energy of the heated exhaust gas exiting the last stage of the gas turbine into potential energy in the form of increased static pressure. Once delivered to the HRSG system, the heated exhaust gas may traverse a series of heat exchanger elements, such as superheaters, re-heaters, evaporators, economizers, and so forth. The heat exchanger elements may be used to transfer heat from the heated exhaust gas to the water source to generate superheated steam. It is a design objective to promote uniform flow through the exhaust gas plenum without negatively impacting diffuser performance, i.e., enabling flow diffusion without appreciable total pressure loss.
BRIEF DESCRIPTION OF THE INVENTION
[0003] In one embodiment, there is provided an exhaust gas diffuser for a turbomachine comprising a diffuser supported in a turbine rotor, aligned with an axis of the turbine rotor, the diffuser configured to re-direct turbine exhaust gas substantially ninety degrees from a first direction of flow along the axis; a plenum chamber in fluid communication with and surrounding an outlet end of the diffuser, the plenum chamber in fluid communication with a transition duct adapted to supply the exhaust gas to another turbomachine; wherein the plenum chamber expands in volume in a direction toward the transition duct.
[0004] In another embodiment, there is provided a turbomachine comprising a gas turbine section including a turbine rotor; a radial diffuser disposed along a first axis of the turbine rotor; an exhaust plenum comprising an inlet receiving a portion of the radial diffuser, the exhaust plenum extending along a second axis substantially perpendicular to the first axis, the plenum chamber expanding in volume along the second axis.
[0005] In still another embodiment, there is provided a combined cycle system comprising: a gas turbine including a turbine rotor extending along a first axis; a heat recovery steam generator; a steam turbine adapted to receive steam from the heat recovery steam generator; a radial diffuser disposed along the first axis; and an exhaust plenum comprising an inlet receiving a portion of the radial diffuser, the exhaust plenum extending along a second axis substantially perpendicular to the first axis, the plenum chamber expanding in volume along the second axis and communicating with the heat recovery steam generator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0007] FIG. 1 is a schematic flow diagram of an embodiment of a combined cycle power generation system having a gas turbine, a steam turbine, and an HRSG;
[0008] FIG. 2 is a detailed but partial side section view of an embodiment of the gas turbine of FIG. 1 having heat exchanger elements of the HRSG of FIG. 1 integrated with components of an exhaust diffuser of the gas turbine;
[0009] FIG. 3 is a cut-away perspective view of an exhaust gas plenum of the type which could be employed in the gas turbine of FIG. 2 ;
[0010] FIG. 4 is a partially cut-away top view of the exhaust plenum shown in FIG. 3 ;
[0011] FIG. 5 is a perspective view of an exhaust gas diffuser and plenum in accordance with an exemplary but nonlimiting embodiment of the invention;
[0012] FIG. 6 is another perspective view of the exhaust gas diffuser and plenum shown in FIG. 5 ; and
[0013] FIG. 7 is a top plan view of the exhaust gas diffuser and plenum shown in FIGS. 5 and 6 .
[0014] FIG. 8 illustrates HRSG inlet profiles at the plenum exit and at the downstream edge of the transition section.
DETAILED DESCRIPTION OF THE INVENTION
[0015] One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0016] When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Any examples of operating parameters are not exclusive of other parameters of the disclosed embodiments.
[0017] FIG. 1 is a schematic flow diagram of an embodiment of a combined cycle power generation system 10 having a gas turbine, a steam turbine, and an HRSG. Specifically, the system 10 may include a gas turbine 12 for driving a first load 14 . The first load 14 may be, for instance, an electrical generator for producing electrical power. The gas turbine 12 may include a turbine 16 , a combustor 18 , and a compressor 20 . The system 10 may also include a steam turbine 22 for driving a second load 24 . The second load 24 may also be an electrical generator for generating electrical power. It will be understood, however, that both the first and second loads 14 , 24 may be other types of loads capable of being driven by the gas turbine 12 and steam turbine 22 . In addition, although the gas turbine 12 and steam turbine 22 may drive separate loads 14 and 24 , as shown in the illustrated embodiment, the gas turbine 12 and steam turbine 22 may also be utilized in tandem to drive a single load via a single shaft. In the illustrated embodiment, the steam turbine 22 may include one low-pressure section 26 (LP ST), one intermediate-pressure section 28 (IP ST), and one high-pressure section 30 (HP ST). However, the specific configuration of the steam turbine 22 , as well as the gas turbine 12 , may be implementation-specific and may include any combination of sections and/or stages.
[0018] The system 10 may also include a multi-stage HRSG 32 . The simplified depiction of the HRSG 32 and its components are not intended to be limiting. Rather, the illustrated HRSG 32 is shown to convey the general arrangement of such systems. Heated exhaust gas 34 from the gas turbine 12 may be transported into the HRSG 32 and used to heat steam used to power the steam turbine 22 . Exhaust from the low-pressure section 26 of the steam turbine 22 may be directed into a condenser 36 . Condensate from the condenser 36 may, in turn, be directed into a low-pressure section of the HRSG 32 with the aid of a condensate pump 38 .
[0019] The condensate may then flow through a low-pressure economizer 40 (LPECON), which is a device configured to heat feedwater with gases, may be used to heat the condensate. From the low-pressure economizer 40 , the condensate may either be directed into a low-pressure evaporator 42 (LPEVAP) or to an intermediate-pressure economizer 44 (IPECON). Steam from the low-pressure evaporator 42 may be returned to the low-pressure section 26 of the steam turbine 22 . Likewise, from the intermediate-pressure economizer 44 , the condensate may either be directed into an intermediate-pressure evaporator 46 (IPEVAP) or to a high-pressure economizer 48 (HPECON). In addition, steam from the intermediate-pressure economizer 44 may be sent to a fuel gas heater (not shown) where the steam may be used to heat fuel gas for use in the combustor 18 of the gas turbine 12 . Steam from the intermediate-pressure evaporator 46 may be sent to the intermediate-pressure section 28 of the steam turbine 22 .
[0020] Finally, condensate from the high-pressure economizer 48 may be directed into a high-pressure evaporator 50 (HPEVAP). Steam exiting the high-pressure evaporator 50 may be directed into a primary high-pressure superheater 52 and a finishing high-pressure superheater 54 , where the steam is superheated and eventually sent to the high-pressure section 30 of the steam turbine 22 . Exhaust from the high-pressure section 30 of the steam turbine 22 may, in turn, be directed into the intermediate-pressure section 28 of the steam turbine 22 , and exhaust from the intermediate-pressure section 28 of the steam turbine 22 may be directed into the low-pressure section 26 of the steam turbine 22 .
[0021] An inter-stage attemperator 56 may be located in between the primary high-pressure superheater 52 and the finishing high-pressure superheater 54 . The inter-stage attemperator 56 may allow for more robust control of the exhaust temperature of steam from the finishing high-pressure superheater 54 .
[0022] In addition, exhaust from the high-pressure section 30 of the steam turbine 22 may be directed into a primary re-heater 58 and a secondary re-heater 60 where it may be re-heated before being directed into the intermediate-pressure section 28 of the steam turbine 22 . The primary re-heater 58 and secondary re-heater 60 may also be associated with an inter-stage attemperator 62 for controlling the exhaust steam temperature from the re-heaters.
[0023] In combined cycle systems such as system 10 , hot exhaust may flow from the gas turbine 12 and pass through the HRSG 32 and may be used to generate high-pressure, high-temperature steam. The steam produced by the HRSG 32 may then be passed through the steam turbine 22 for power generation. In addition, the produced steam may also be supplied to any other processes where superheated steam may be used. The gas turbine 12 generation cycle is often referred to as the “topping cycle,” whereas the steam turbine 22 generation cycle is often referred to as the “bottoming cycle.” By combining these two cycles as illustrated in FIG. 1 , the combined cycle power generation system 10 may lead to greater efficiencies in both cycles. In particular, exhaust heat from the topping cycle may be captured and used to generate steam for use in the bottoming cycle.
[0024] Therefore, one aspect of the combined cycle power generation system 10 is the ability to recapture heat from the heated exhaust gas 34 using the HRSG 32 . As illustrated in FIG. 1 , components of the gas turbine 12 and the HRSG 32 may be separated into discrete functional units. In other words, the gas turbine 12 may generate the heated exhaust gas 34 and direct the heated exhaust gas 34 toward the HRSG 32 , which may be primarily responsible for recapturing the heat from the heated exhaust gas 34 by generating superheated steam. In turn, the superheated steam may be used by the steam turbine 22 as a source of power. The heated exhaust gas 34 may be transferred to the HRSG 32 through ductwork, which may vary based on the particular design of the combined cycle power generation system 10 .
[0025] A more detailed illustration of how the gas turbine 12 functions may help illustrate how the heated exhaust gas 34 may be transferred to the HRSG 32 from the gas turbine 12 . Accordingly, FIG. 2 is a detailed side view of an embodiment of the gas turbine 12 of FIG. 1 having heat exchanger elements of the HRSG 32 of FIG. 1 integrated with components of an exhaust diffuser of the gas turbine 12 . As described with respect to FIG. 1 , the gas turbine 12 may include the turbine 16 , the combustor 18 , and the compressor 20 . Air may enter through an air intake 64 and be compressed by the compressor 20 . Next, the compressed air from the compressor 20 may be directed into the combustor 18 where the compressed air may be mixed with fuel gas. The fuel gas may be injected into the combustor 18 through a plurality of fuel nozzles 66 . The mixture of compressed air and fuel gas is generally burned within the combustion chamber of the combustor 18 to generate a high-temperature, high-pressure combustion gas, which may be used to generate torque within the turbine 16 . A rotor of the turbine 16 may be coupled to a rotor of the compressor 20 , such that rotation of the turbine rotor may also cause rotation of the compressor 20 . In this manner, the turbine 16 drives the compressor 20 as well as the load 14 (not shown in FIG. 2 ). Exhaust gas from the turbine 16 section of the gas turbine 12 may be directed into an exhaust diffuser 68 . In the embodiment of FIG. 2 , the exhaust diffuser 68 may be a radial exhaust diffuser, whereby the exhaust gas may be re-directed by exit guide vanes 70 to exit the exhaust diffuser 68 through a 90-degree turn outwardly (i.e., radially) through an exhaust plenum (not shown) and a transition inlet to the HRSG 32 .
[0026] Another aspect of certain components of the exhaust diffuser 68 , in addition to directing the heated exhaust gas 34 to the HRSG 32 , may be to ensure that certain aerodynamic properties of the heated exhaust gas 34 are achieved. For instance, an exhaust frame strut 72 , illustrated in FIG. 2 , may be cambered with an airfoil wrapped around it. The exhaust frame strut 72 may also be rotated such that swirling of the heated exhaust gas 34 may be minimized and flow of the heated exhaust gas 34 may generally be more axial in nature until flowing through the exit guide vanes 70 . In addition, the exit guide vanes 70 may also be designed in such a way that, when the heated exhaust gas 34 is turned toward the exhaust plenum at a 90-degree angle, the exit guide vanes 70 minimize the aerodynamic loss incurred in turning the flow 90 degrees radially. Therefore, proper aerodynamic design of the exhaust frame strut 72 , exit guide vanes 70 , as well as other components of the exhaust diffuser 68 within the flow path of the heated exhaust gas 34 , may be a design consideration.
[0027] FIG. 3 is a cut-away perspective view of an embodiment of a diffuser that may be similar to the diffuser 68 in FIG. 2 , but for convenience, it will be appreciated that the diffuser is not shown to the same scale as in FIG. 2 . The diffuser 68 connects to a plenum 74 which, along with guide vanes 46 , redirects the exhaust gas substantially ninety (90) degrees and into the transition duct 76 which connects to the HRSG inlet (not shown). The radial guide vanes 46 may be circular (e.g., tapered annular or conical structures) and disposed concentrically about the x-axis 31 . The plenum 74 then gradually guides the combustion gases along the z-axis 35 , into the expanding transition section 76 which is connected to the inlet to the HRSG.
[0028] The plenum 74 in the known configuration shown in FIGS. 3 and 4 is generally square or rectangular in shape, but with a slanted end wall portion 78 extending from the top wall 80 to a side wall 82 . Walls 80 and 82 are substantially perpendicular to each other, while upstream and downstream sides 84 , 86 , respectively, are parallel as best seen in FIG. 4 . The bottom wall 88 is parallel to the top wall 80 , but may have a slanted component 90 between the bottom wall 88 and the side wall 82 .
[0029] FIGS. 5-7 illustrate a modified plenum 100 in accordance with an exemplary but nonlimiting embodiment of the invention. The radial diffuser 101 is received within the plenum inlet, concentric to the turbine rotor axis 114 ( FIG. 7 ). In this example, the plenum 100 is formed with a radiused end defined by a curved end wall 102 merging with top and bottom walls 104 , 106 . The curved end wall 102 and top and bottom walls 104 , 106 collectively form a peripheral edge wall upstream and downstream side walls 108 , 110 , respectively, which extend from the radiused end wall 102 to the expanding transition section 112 . The curved end wall 102 is drawn on the center axis 114 of the diffuser 101 (here again, not drawn to scale), and the top and bottom walls 104 , 106 extend tangentially, in parallel, from opposite ends of the radiused end wall. Note that the straight top and bottom walls 104 , 106 cross the axis 114 of the diffuser/turbine rotor.
[0030] It will be understood that the internal vane components of the diffuser may be similar to the arrangement shown in FIG. 3 .
[0031] Significantly, the upstream and downstream side walls 108 and 110 are not parallel. As best seen in FIG. 7 , the downstream side wall 110 is perpendicular to the center axis 114 , but the upstream side wall 108 extends at an angle of between 20 and 50 degrees (and preferably between 35 and 45 degrees) relative to the downstream side wall 110 . This expansion of the flow path from the plenum 100 to the transition section 112 promotes a redistribution to uniform flow of gases to the HRSG inlet without impact on diffuser performance. In fact, the uniform flow not only benefits HRSG performance, but also simplifies the design of the HRSG silencer located in the HRSG inlet. The plenum design described herein also enables relatively flat inlet profiles across operating conditions, and across a range of last stage turbine bucket exit profiles.
[0032] FIG. 8 illustrates HRSG inlet profiles at the plenum exit plane 116 and at the downstream edge 118 of the transition section 112 . The Y-axis “% Span” refers to the height of the plenum, from bottom to top. It can be seen that the “total Velocity” of air flow through the plenum is relatively uniform across the height of the plenum.
[0033] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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An exhaust gas diffuser for a turbomachine includes a diffuser supported on a turbine rotor, aligned with an axis of said turbine rotor. The diffuser is configured to re-direct turbine exhaust gas substantially ninety degrees from a first direction of flow along the rotor axis. A plenum chamber is in fluid communication with and surrounds an outlet end of the diffuser. The plenum chamber is in fluid communication with a transition duct adapted to supply the exhaust gas to another turbomachine. The plenum chamber expands in volume between the diffuser and the transition duct.
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[0001] This application is a continuation of U.S. application Ser. No. 10/494,251, filed Sep. 13, 2004, which claims priority to and all the benefits of International Application No. PCT/CA02/01685, filed Nov. 4, 2002, which claims priority to and all the benefits of U.S. Provisional Application No. 60/335,315, filed Nov. 2, 2001.
FIELD OF THE INVENTION
[0002] The invention relates to an anti-pinch system for a closure system associated with an aperture of a motor vehicle. More specifically, the invention relates to an anti-pinch system for an aperture of a motor vehicle wherein the anti-pinch system differentiates a number of zones.
DESCRIPTION OF THE RELATED ART
[0003] Motor vehicles typically have anti-pinch systems associated with powered closure assemblies used to selectively open and close an aperture. By way of example only, an aperture of a motor vehicle is found within a door or side and the closure panel associated therewith is a window and its associated control mechanism. A non-exhaustive list of closure assemblies includes door windows, sliding doors, liftgates, deck-lids, sunroofs and the like.
[0004] The anti-pinch systems associated with these closure assemblies typically sense the presence of a foreign object in the path of the closure panel by using characteristics such as motor current or a feedback device, such as a Hall effect sensor, position sensors, tachometer and the like. These feedback devices sense an abnormal characteristic in the parameter being sensed relative to the normal or unobstructed operating characteristic of the closure panel.
[0005] U.S. Pat. No. 6,051,945, issued to Furukawa on Apr. 18, 2000, discloses an anti-pinch assembly for a closure panel. A processor controls a motor that moves the windowpane between its open and closed positions. A Hall effect sensing device is positioned such that it can sense the velocity of the output shaft of the motor. To measure velocity, the Hall effect sensors are disposed around the shaft of the motor. A magnet is secured to the shaft and provides the magnetic field required sensed by the Hall effect sensors. Once the velocity of the shaft is measured, acceleration is derived and the force is calculated using the mass of the windowpane. This system requires the use of multiple sensors and calculations to determine the presence of an object.
[0006] Simple detection of obstructions based on motor speed or electrical current passing through the motor are inadequate due to the normally varying characteristics of these parameters through the full range of motion for the closure panel.
SUMMARY OF THE INVENTION
[0007] The disadvantages of the prior art may be overcome by providing an anti-pinch assembly that prevents objects from getting caught by a closure panel of a motor vehicle by providing an anti-pinch system having multiple zones of varying sensitivity.
[0008] According to one aspect of the invention, there is provided an anti-pinch assembly is used for a closure panel supported by the motor vehicle. The closure panel is movable between an open position and a closed position. A controller is operably connected to the closure panel for controlling the operation of the closure panel. A position sensor is connected to the controller for indicating the position of the closure panel as the closure panel moves between the open and closed positions. A capacitive sensor is mounted on the frame of the vehicle and connected to the controller for providing an output signal to the controller indicative of the presence of a foreign object in the path of the closure panel. The controller varies the function of the capacitive sensor through a plurality of threshold levels as a function of the position of the closure panel as indicated by the position indicator. In a critical zone of travel, namely, travel of the closure panel nearing the closed position, the capacitive sensor can be utilized in either a contact mode or a non-contact mode or a combination of both.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Advantages of the invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0010] FIG. 1 is a schematic of one embodiment of the invention;
[0011] FIG. 2 is a side view of an aperture in a door of a motor vehicle incorporating one embodiment of the invention;
[0012] FIG. 3 is a schematic view of the driving circuit for the invention of FIG. 1 ;
[0013] FIG. 4 is a cross section of a portion of an aperture and a window pane disposed adjacent a graphic representation of zones; and
[0014] FIG. 5 is a cross section of graph of an aperture and a windowpane incorporating adhesive based sensor strips.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Referring to the Figures, an anti-pinch assembly is generally indicated at 10 . The anti-pinch assembly 10 is used in conjunction with a closure panel assembly. The closure panel assembly includes of a closure panel 12 , defining a leading edge 13 , and its operating system, discussed subsequently. The closure panel 12 travels along a path between open and closed positions. The anti-pinch assembly 10 prevents the closure panel 12 from pinching or crushing an obstruction or object (not shown) that may be extending through an aperture 14 of a motor vehicle 16 (both shown in FIG. 2 ) when the closure panel 12 nears the closed position. It should be appreciated by those skilled in the art that the closure panel 12 may be any motorized or automated structure that moves between an open position and a closed position. By way of example, a non-exhaustive list of closure panels 12 include windowpanes, doors, liftgates, sunroofs and the like. Apertures include window frames, door openings, sunroof openings and the like. For purposes of simplicity, the remainder of this disclosure will focus on the windowpane and window frame combination.
[0016] The anti-pinch assembly 10 includes a controller 18 . The controller 18 is electrically connected, directly or indirectly, to a power source 20 . A conductor 22 graphically represents this connection. The power source 20 is preferably the power source 20 for the motor vehicle 16 . The power source 20 may be a battery, a generator or any other electricity generating device or combination thereof.
[0017] A motor 24 receives electricity through a conductor 26 that, directly or indirectly, operatively extends between the power source 20 and the motor 24 . The motor 24 rotates a shaft 28 operatively connected to the closure panel 12 in a conventional manner. The operative connection transforms the rotational energy into mechanical energy. More specifically, the electric output of the motor 24 into an opening and closing movement of the closure panel 12 . The motor 24 optionally may be provided with separate motor controller. Operation of the motor 24 is effected by the motor controller.
[0018] A position sensor 30 is disposed adjacent the motor 24 . The position sensor 30 identifies the position of the shaft 28 of the motor 24 and generates a position signal. By identifying the position of the shaft 28 upon receipt of the position signal, the controller 18 determines with specificity the position of the leading edge 13 of the closure panel, i.e., the windowpane 12 . As the shaft 28 rotates, the position sensor 30 identifies where along the rotation the shaft 28 is as well as how many rotations the shaft 28 has executed. The degree of accuracy of the position sensor 30 is a variable that will depend on the specific design.
[0019] In one embodiment, the position sensor 30 is a Hall effect sensor that utilizes a single magnet (not shown) that is secured to the shaft 28 . The magnet rotates with the shaft 28 and its magnetic field affects the position sensor 30 as it passes thereby.
[0020] In an alternative embodiment, the position sensor is a Hall effect sensor that is secured to a portion of the mechanism (not shown) that moves the windowpane between the open and closed positions. The position sensor 30 could be secured to a drive screw, glass run channel or some other portion of the mechanism that moves proportionally to the windowpane or closure panel 12 .
[0021] A capacitive sensor 32 is mounted relative to the window frame in a spaced relation and electrically connected to the controller 18 .
[0022] The capacitive sensor 32 is capable of determining changes in magnetic fields in the surrounding space due to the introduction of an object that has a dielectric that is different than that of the surrounding space. The capacitive sensor 32 can be turned to detect smaller changes in the surrounding space, i.e., when an object is extending through the window frame 40 but not touching the window frame 40 , referred to as a non-contact mode. The capacitive sensor 32 detects changes in the surrounding space defined by the aperture 14 by measuring the capacitance of the capacitive sensor 32 , discussed subsequently. Changes occur prior to the immediate closing of the closure panel 12 and when an object extends therethrough. An object extending through the aperture 14 will disrupt the dielectric fields being measured by the capacitive sensor 32 and the sensor 32 will responsively generate an output signal relative thereto.
[0023] The capacitive sensor 32 may also be used in a second mode, i.e., a contact mode. In the contact mode, the sensitivity of the capacitive sensor 32 is reduced. Therefore, a change in the dielectric field surrounding the capacitive sensor 32 triggers the anti-pinch assembly 10 only when the capacitive sensor 32 is moved by the object when it actually contacts the sensor 32 or the sealing system 37 that houses the sensor 32 . The sensitivity of the sensor 32 is reduced so that the leading edge 13 of the closure panel 12 does not trigger the anti-pinch assembly 10 , which would result in the closure panel 12 failing to reach its closed position ever.
[0024] Referring to FIG. 4 , the capacitive sensor 32 is molded into a flexible, and/or low durometer compound, in a range of less than 40-50 Shore. The compound is flexible and configured as the sealing system 37 of the aperture 14 . Flexibility of the sealing system 37 can also be controlled by the cross-sectional configuration, including controlling thickness of the arm and walls supporting the capacitive sensor. In the embodiment shown in FIG. 4 , the capacitive sensor 32 is molded directly into the sealing system 37 .
[0025] Referring to FIG. 5 , wherein like primed numerals represent similar elements in an alternative embodiment, the capacitive sensor 32 ′ may be added as an aftermarket item by using adhesive 39 to attach the capacitive sensor 32 ′ to the sealing system 37 ′.
[0026] Referring to FIG. 2 , a door 36 of a motor vehicle 16 is shown. The door 36 defines the aperture 14 (a window frame in this case) as an opening extending between a base 38 of the door 36 and around a window frame 40 having a forward boundary 42 , an upper boundary 44 and a rearward boundary 46 . The capacitive sensor 32 extends along the forward 42 and upper 44 boundaries. The capacitive sensor 32 is designed to measure the electromagnetic field directly therebelow within the aperture 14 .
[0027] The capacitive sensor 32 is preferably a long conductor that extends out from and along a window frame 40 at a predetermined distance from the window frame 40 . The predetermined distance creates a specific capacitance for the capacitive sensor 32 because the capacitive sensor 32 uses the window frame 40 as ground. Any changes in the distance between the capacitive sensor 32 and the window frame 40 changes the capacitance in a manner far greater than when an object extends through the window frame 40 but does not touch the capacitive sensor 32 . This change in capacitance is monitored by the controller 18 . If an object, regardless of its dielectric constant, contacts the capacitive sensor 32 enough to flex it out of its position, the change is detected by the controller 18 , which will subsequently stop and/or reverse the closure of the window.
[0028] The controller 18 includes a threshold generator 33 that generates a threshold value for the capacitive sensor 32 . This threshold determines in which zone the anti-pinch assembly 10 is operating. The threshold is a value of a dielectric that the capacitive sensor 32 can detect. The threshold generator 33 includes a pulse generator 34 and a threshold capacitor 35 . The threshold capacitor 35 is connected in parallel with the capacitive sensor 32 and is approximately 1000 times the capacitance of the capacitive sensor 32 . The pulse generator 34 generates a regular pulse train of less than 5 volts, preferably 3-5 volts at a frequency of about 12 Mhz (200-500 ns per pulse), which signal is applied to the capacitive sensor 32 . Since the capacitive sensor 32 is small in comparison with the threshold capacitor 35 , the capacitive sensor 32 will become fully charged quickly. Once charged, the pulse train is reflected back to the threshold capacitor 35 thereby charging it in a stepped manner, graphically represented at 39 , until the threshold capacitor 35 is fully charged. A counter 137 counts the number of pulses required to fully charge the threshold capacitor 35 and the count is placed in a floating memory. The capacitors 32 , 35 are then discharged or reset and the process is re-started.
[0029] The count can be averaged over time so that the effects of weather and other extrinsic conditions can be factored out. A comparator 45 compares the counts of successive counts.
[0030] The determination of the presence of an obstacle is performed by monitoring the count. A measured signal is generated based on the monitored count. Any obstacle, whether it be a body part or otherwise, extending into the window aperture 14 or contacting the seal 44 will affect the dielectric constant of the field. The number of pulses required to fully charge the threshold capacitor 35 will increase should an object be present, resulting in an increased measured signal. If the change between a predetermined number of successive counts deviates or increases beyond a first predetermined threshold signal or count, the controller 18 determines that an object has extended through the window frame 40 or has moved the capacitive sensor 32 by touching or moving the sealing system 37 .
[0031] When detection of an obstacle is made, the controller 18 then changes the motor signal being sent to the motor 24 . The new motor control signal directs the motor 24 to either stop the closure panel 12 from moving or to reverse the direction in which the shaft 28 is rotating, retracting the closure panel 12 . If the closure panel 12 is returned to its open position, the controller 18 normalizes the motor control signal and allows the motor 24 to operate according to normal operation. If the closure panel 12 remains in the same position, the anti-pinch assembly 10 will not allow the closure panel 12 to continue to its closed position until after the compare value is eliminated.
[0032] As noted previously, the motor may be provided with a separate motor controller having a position sensor. Thus, the motor controller will provide a position signal to the controller 18 and the controller 18 will send a motor control signal back to the motor controller.
[0033] Referring to FIG. 4 , a graphic representation of multiple zones is generally shown at 56 . The graph 56 shows each zone 58 , 60 , 62 as a function of position or location of the leading edge 13 of the windowpane 12 . Each different zone 58 , 60 , 62 is contiguous with the next such that the leading edge 13 of the windowpane 12 can never in a position where controller 18 is not monitoring the capacitance of the capacitive sensor 32 . Each of the zones 59 , 60 , 62 is a graphic representation for each of a plurality of threshold values above which the count must reach before the anti-pinch assembly 10 stops or reverses the windowpane 12 .
[0034] In the lower or primary zone 58 , the controller 18 increases the sensitivity of the capacitive sensor 32 to allow it to detect the presence of an object even when the object is low enough to avoid physically moving the capacitive sensor 32 .
[0035] In the secondary zone 60 , usually about 4 mm separating the upper edge 13 of the windowpane 12 from the sensor 32 , the controller 18 decreases the sensitivity of the capacitive sensor 32 . The position sensor 30 generates the position signal and the controller 18 responsively determines when the windowpane 12 enters the secondary zone 60 .
[0036] In this zone of operation, the ability to detect an object is reduced. In other words, the controller 18 applies a second predetermined threshold that has a magnitude and/or duration greater than the first predetermined threshold.
[0037] The reduction in sensitivity allows the windowpane 12 to approach the capacitive sensor 32 without the controller 18 misidentifying the windowpane 12 as an object that might be pinched between the windowpane 12 and the window frame 40 . As may be appreciated by those skilled in the art, a decrease of sensitivity still allows the capacitive sensor 32 to detect an object contacting it. Therefore, should an object remain in the path of the windowpane 12 as the upper edge 13 approaches the sealing system 37 , the controller 18 will still be able to detect it and stop or retract the windowpane 12 .
[0038] In the optional third or upper zone 62 of operation, the controller 18 deactivates the capacitive sensor 32 . This allows the windowpane 12 to enter the sealing system 37 to properly seal against thereto. The capacitive sensor 32 is deactivated because, depending on the sealing system 37 ; the capacitive sensor 32 may move upon entry. If it were still active, it would inhibit the closing of the window or aperture 14 . Upon the windowpane 12 being retracted, the controller 18 reverts to the reduced sensitivity mode (intermediate zone 60 ) and, subsequently, the higher sensitivity mode (lower zone 58 ). The anti-pinch assembly 10 will remain active until the windowpane 12 is returned to its closed position abutting the sealing system 37 .
[0039] The invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described.
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An anti-pinch assembly is used for a closure panel movable between open and closed positions on a motor vehicle. A controller operably connected to the closure panel controls operation thereof. A position sensor connected to the controller indicates the position of the closure panel between the open and closed positions. A capacitive sensor mounted on the vehicle and connected to the controller provides an output signal to the controller indicative of the presence of a foreign object in the path of the closure panel. The controller varies the function of the capacitive sensor through a plurality of threshold levels as a function of the position of the closure panel as indicated by the position indicator. In a critical zone of travel with the closure panel nearing the closed position, the capacitive sensor can be utilized in either a contact mode or a non-contact mode or a combination of both.
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FIELD OF THE PRESENT INVENTION
The present invention relates generally to apparatus for pressure-pulse therapy. The present invention relates in particular to the generation of compound pressure pulses especially for orthopedic therapy.
BACKGROUND OF THE PRESENT INVENTION
Pressure-pulse therapy, also known as shock-wave therapy, has many uses. It is used in lithotripsy as a non-invasive technique for pulverizing kidney stones and calculi in the bladder and urethra. It is also used for dissolving lipids in cells close to the skin and in the pelvic region. In particular, it has many uses in orthopedic medicine, for example, as a therapeutic means for any of the following:
i. osteoporosis and the inducement of bone growth;
ii. joining of bone fracture, especially, ununion fractures, i.e., fractures that have failed to unite and heal;
iii. disintegration of calculi and (or) calcification in fibers, joints, and tendinitis; and
iv. pain relief in the cases of calcific tendinitis of the shoulder joint, tennis elbow, golf elbow, and plantar fasciitis (with and without heel spur).
U.S. Pat. No. 4,620,545 “Non-Invasive Destruction of Kidney Stones” to Shene et al., whose disclosure is incorporated herein by reference, describes a pressure-pulse therapy apparatus which includes an ellipsoidal reflector, having a first focal point within the reflector's dome and a second focal point outside the reflector's dome. A flexible diaphragm caps the reflector, and the region contained by the reflector and the diaphragm is filled with a liquid medium, for pulse propagation. A pressure-pulse source is located at the first focal point, within the medium. This configuration provides that a portion of a pulse originating from the source, at the first focal point, will impinge on the reflector, be reflected by it, and be brought into focus at the second focal point. The reflector is movable and can be positioned so that the second focal point coincides with a concretion within the body that is to be pulverized. Sonic aiming means are used to detect the concretion and to direct the positioning of the reflector.
In general, pressure-pulse therapy is accompanied by an imaging means, such as the sonic aiming means of U.S. Pat. No. 4,620,545. The region for treatment is generally small, between 0.3 and 1.5 cm, and it is desirous to image the location in order for the therapy to be applied effectively. X-ray imaging may be used; however, with x-rays, the patient and the physician are exposed to radiation doses with each treatment.
PCT patent publication PCT WO 93/14720, “Method and Apparatus Particularly Useful for Treating Osteoporosis,” to Spector, whose disclosure is incorporated herein by reference, offers an alternative to the need for an imaging means. It has a generally parabolic reflector, which has a single focal point within the reflector's dome. A flexible diaphragm caps the reflector and the region contained by the reflector and the diaphragm is filled with a liquid medium, as in the previous patent. A pressure-pulse source is located at the focal point, within the liquid. This configuration provides that a portion of a pulse originating from the source, at the focal point, will impinge on the reflector, and be reflected by it, collimated. In other words, the reflected pulse will be a non-focusing wave, so focusing means are not essential. Pressure pulse therapy can thus be image free.
However, with a collimated beam, some pressure pulse energy is lost, when compared with a beam that is focused at the region for treatment. It would be desirable to direct more of the pressure-pulse energy at the region for treatment, without being dependent on an imaging means.
SUMMARY OF THE PRESENT INVENTION
The present invention seeks to provide a therapeutic pressure pulse formed as a compound pressure pulse of at least two subordinate pulses.
There is thus provided, in accordance with the present invention, a dome-shaped reflector, having:
a center section, having predetermined first curvature and reflective characteristics associated therewith, and formed to reflect a primary pressure pulse propagating thereon, so as to form a first subordinate pressure pulse of a compound pressure pulse; and
at least one ring section, substantially concentric with said center section, having predetermined second curvature and reflective characteristics associated therewith, and formed to reflect the primary pressure pulse propagating thereon, so as to form at least one additional subordinate pressure pulse of said compound pressure pulse.
Additionally, in accordance with the present invention, said center section is substantially parabolic and has a single focal point.
Further in accordance with the present invention, said at least one ring section is substantially ellipsoid and has proximal and distal focal points with respect to said reflector, wherein said focal point of said center section and said proximal focal point of said at least one ring section substantially coincide.
Additionally, in accordance with the present invention, said at least one ring section includes a plurality of substantially ellipsoid ring sections, each having proximal and distal focal points with respect to said reflector, wherein said proximal focal points of said plurality of ring sections substantially coincide, wherein said distal focal points of said plurality of ring sections are adjacent to each other, and wherein said focal point of said center section and said proximal focal points of said plurality of ring sections substantially coincide.
Alternatively, said center section and said at least one ring section are substantially ellipsoid, each having proximal and distal focal points with respect to said reflector, wherein said proximal focal point of said center section and said proximal focal point of said at least one ring section substantially coincide.
Alternatively, said center section is generally parabolic and has a single focal zone.
Additionally, said at least one ring section is generally ellipsoid and has proximal and distal focal zones with respect to said reflector, wherein said focal zone of said center section and said proximal focal zone of said at least one ring section generally coincide.
Additionally, said at least one ring section includes a plurality of generally ellipsoid ring sections, each having proximal and distal focal zones with respect to said reflector, wherein said proximal focal zones of said plurality of ring sections generally coincide, wherein said distal focal zones of said plurality of ring sections are generally adjacent to each other, and wherein said focal zone of said center section and said proximal focal zones of said plurality of ring sections generally coincide.
Alternatively, said center section and said at least one ring section are generally ellipsoid, each having proximal and distal focal zones with respect to said reflector, wherein said proximal focal zone of said center section and said proximal focal zone of said at least one ring section generally coincide.
Alternatively, said predetermined curvatures and reflective characteristics are determined by numerical analysis.
Additionally, said predetermined curvatures and reflective characteristics include a predetermined zone at which both said first subordinate pressure pulse and said at least one additional subordinate pressure pulse are reflected.
Alternatively, said predetermined curvatures and reflective characteristics include:
a predetermined point at which said first subordinate pressure pulse is reflected; and
a predetermined point at which said at least one additional subordinate pressure pulse is reflected.
Alternatively, said predetermined curvatures and reflective characteristics include:
a predetermined zone at which said first subordinate pressure pulse is reflected; and
a predetermined zone at which said at least one additional subordinate pressure pulse is reflected.
Alternatively, said predetermined first curvature is selected from a group which consists of generally parabolic, substantially parabolic, generally ellipsoid, substantially ellipsoid, and a curvature which is determined by numerical analysis to yield said predetermined first reflective characteristics.
Additionally, said predetermined second curvature is selected from a group which consists of generally parabolic, substantially parabolic, generally ellipsoid, substantially ellipsoid, and a curvature which is determined by numerical analysis to yield said predetermined second reflective characteristics.
Further in accordance with the present invention, said predetermined curvature and reflective characteristics include a predetermined phase difference between said first subordinate pressure pulse and said at least one additional subordinate pressure pulse.
Additionally, in accordance with the present invention, said phase difference is between 0.5 and 1 microsecond.
Additionally, in accordance with the present invention, said at least one ring section, having predetermined second curvature and reflective characteristics associated therewith, includes a plurality of ring sections, each having predetermined curvature and reflective characteristics associated therewith, formed to reflect a primary pressure pulse propagating thereon, from said pressure-pulse source, so as to form a plurality of additional subordinate pressure pulses of the compound pulse, wherein said plurality of additional subordinate pressure pulses of the compound pulse include predetermined phase differences between them.
There is thus also provided, in accordance with the present invention, a dome-shaped reflector, having:
a center section, having predetermined first curvature and reflective characteristics associated therewith, and formed to reflect a primary pressure pulse propagating thereon, so as to form a first subordinate pressure pulse of a compound pressure pulse; and
at least one ring section, generally concentric with said center section, having predetermined second curvature and reflective characteristics associated therewith, and formed to reflect the primary pressure pulse propagating thereon, so as to form at least one additional subordinate pressure pulse of said compound pressure pulse.
There is thus also provided, in accordance with the present invention, pressure-pulse therapy apparatus, which includes:
a dome-shaped reflector, having:
a center section, having predetermined first curvature and reflective characteristics associated therewith, and formed to reflect a primary pressure pulse propagating thereon, so as to form a first subordinate pressure pulse of a compound pressure pulse; and
at least one ring section, substantially concentric with said center section, having predetermined second curvature and reflective characteristics associated therewith, and formed to reflect the primary pressure pulse propagating thereon, so as to form at least one additional subordinate pressure pulse of said compound pressure pulse;
an x-axis passing through its center;
an open end;
a flexible diaphragm, which caps said open end;
a fluid medium contained within said reflector and said diaphragm, for facilitating propagation of the pressure pulses;
a pressure-pulse source, immersed in said medium, located between said reflector and said diaphragm, on said x-axis, for generating the primary pressure pulse; and
a power supply, which supplies power to said pressure-pulse source.
Additionally, in accordance with the present invention, said first and second curvatures and reflective characteristics are associated with a point P, located on said x-axis, wherein said pressure-pulse source is located at said point P.
Alternatively, said first and second curvatures and reflective characteristics are associated with a point P, located on said x-axis, wherein said pressure-pulse source is located at a point P″ on said x-axis.
Additionally, said point P is more proximal to said reflector than said point P″.
Alternatively, said point P is more distal to said reflector than said point P″.
Further in accordance with the present invention, said apparatus includes a linear extender for varying a distance between said pressure-pulse source and said reflector, along said x-axis.
Additionally, in accordance with the present invention, said pressure-pulse source is selected from a group which consists of substantially and generally point pressure-pulse sources.
Further in accordance with the present invention, said pressure-pulse source is a spark discharge source.
Alternatively, said pressure-pulse source is an electromagnetic pressure-pulse source.
Additionally, in accordance with the present invention, said pressure-pulse is operable to generate primary pressure pulses in the range between 1000 and 6000 bars.
Further in accordance with the present invention, said apparatus is operable to generate, from the primary pressure pulse, subordinate pressure pulses in the range between 5 and 600 bars.
Additionally, in accordance with the present invention, said apparatus is arranged for traveling along at least one axis, for positioning against a tissue surface of a body.
Further in accordance with the present invention, said apparatus is arranged for traveling along a plurality of axes, for positioning against a tissue surface of a body.
Additionally, in accordance with the present invention, said apparatus is arranged for tilting along at least one angular direction, for positioning against a tissue surface of a body.
Further in accordance with the present invention, said apparatus is arranged for tilting along a plurality of angular directions, for positioning against a tissue surface of a body.
Additionally, in accordance with the present invention, said apparatus includes a support fixture for a portion of a body to be treated.
There is thus also provided, in accordance with the present invention, pressure-pulse therapy apparatus, which includes:
a dome-shaped reflector, having:
a center section, having predetermined first curvature and reflective characteristics associated therewith, and formed to reflect a primary pressure pulse propagating thereon, so as to form a first subordinate pressure pulse of a compound pressure pulse; and
at least one ring section, generally concentric with said center section, having predetermined second curvature and reflective characteristics associated therewith, and formed to reflect the primary pressure pulse propagating thereon, so as to form at least one additional subordinate pressure pulse of said compound pressure pulse;
an x-axis passing through its center;
an open end;
a flexible diaphragm, which caps said open end;
a fluid medium contained within said reflector and said diaphragm, for facilitating propagation of the pressure pulses;
a pressure-pulse source, immersed in said medium, located between said reflector and said diaphragm, on said x-axis, for generating the primary pressure pulse; and
a power supply, which supplies power to said pressure-pulse source.
There is thus also provided, in accordance with the present invention, a pressure-pulse therapy method, which includes:
generating a primary pressure pulse;
propagating the primary pressure pulse in a fluid medium;
employing a reflector, having:
a center section, having first curvature and reflective characteristics associated therewith; and
at least one ring section, having second curvature and reflective characteristics associated therewith;
reflecting a first portion of the primary pressure pulse by the center section, thus forming a first subordinate pressure pulse of a compound pressure pulse; and
reflecting at least one additional portion of the primary pressure pulse by the at least one ring section, thus forming at least one additional subordinate pressure pulse of said compound pressure pulse.
Additionally, in accordance with the present invention, reflecting a first portion of the propagation includes reflecting the propagation in a substantially collimated manner.
Alternatively, reflecting a first portion of the propagation includes reflecting the propagation in a generally collimated manner.
Alternatively, reflecting a first portion of the propagation includes reflecting the propagation as a substantially focusing propagation.
Alternatively, reflecting a first portion of the propagation includes reflecting the propagation as a generally focusing propagation.
Additionally, in accordance with the present invention, reflecting at least one additional portion of the propagation includes reflecting the propagation as a substantially focusing propagation.
Alternatively, reflecting at least one additional portion of the propagation includes reflecting the propagation as a generally focusing propagation.
Additionally, in accordance with the present invention, said method includes reflecting the first portion of the primary pressure pulse propagation and reflecting at least one additional portion of the primary pressure pulse propagation with a phase difference between them.
Further in accordance with the present invention, employing a reflector includes employing a reflector formed of a plurality of sections that include:
a center section, having predetermined first curvature and reflective characteristics associated therewith; and
a plurality of ring sections, having predetermined curvatures and reflective characteristics associated therewith,
wherein reflecting at least one additional portion of the primary pressure pulse propagation includes reflecting a plurality of additional portions of the primary pressure pulse propagation by said plurality of sections, thus forming a plurality of additional subordinate pressure pulses.
Additionally, in accordance with the present invention, said method includes reflecting the plurality of additional portions of the primary pressure pulse propagation with phase differences between them.
Further in accordance with the present invention, said method includes varying a distance between the reflector and a pressure-pulse source.
Additionally, in accordance with the present invention, said method includes therapeutically applying the compound pressure pulse to a tissue of a body.
Further in accordance with the present invention, the tissue is human tissue.
There is thus also provided, in accordance with the present invention, a disk-like acoustic lens, having:
a center section, having predetermined first curvature and focusing characteristics associated therewith, and formed to direct a primary pressure pulse propagating thereon, so as to form a first subordinate pressure pulse of a compound pressure pulse; and
at least one ring section, substantially concentric with said center section, having predetermined second curvature and focusing characteristics associated therewith, and formed to direct the primary pressure pulse propagating thereon, so as to form at least one additional subordinate pressure pulse of said compound pressure pulse.
Additionally, in accordance with the present invention, said predetermined curvatures and focusing characteristics are determined by numerical analysis.
Further in accordance with the present invention, said predetermined curvatures and focusing characteristics include a predetermined zone at which both said first subordinate pressure pulse and said at least one additional subordinate pressure pulse are directed.
Alternatively, said predetermined curvatures and focusing characteristics include:
a predetermined point at which said first subordinate pressure pulse is directed; and
a predetermined point at which said at least one additional subordinate pressure pulse is directed.
Alternatively, said predetermined curvatures and focusing characteristics include:
a predetermined zone at which said first subordinate pressure pulse is directed; and
a predetermined zone at which said at least one additional subordinate pressure pulse is directed.
Alternatively, said predetermined curvatures and focusing characteristics include a predetermined phase difference between said first subordinate pressure pulse and said at least one additional subordinate pressure pulse.
Additionally, in accordance with the present invention, said phase difference is between 0.5 and 1 microsecond.
Further, in accordance with the present invention, said at least one ring section, having predetermined second curvature and focusing characteristics associated therewith, includes a plurality of ring sections, each having predetermined curvatures and focusing characteristics associated therewith, formed to reflect a primary pressure pulse propagating thereon, so as to form a plurality of additional subordinate pressure pulses of said compound pressure pulse.
Additionally, in accordance with the present invention, said plurality of additional subordinate pressure pulses of said compound pressure pulse include predetermined phase differences between them.
Additionally, in accordance with the present invention, said lens includes a cutout section that allows a portion of the primary pressure pulse to pass through it, undisturbed.
Additionally, in accordance with the present invention, said cutout section is said center section.
There is thus also provided, in accordance with the present invention, a disk-like acoustic lens, having:
a center section, having predetermined first curvature and focusing characteristics associated therewith, and formed to direct a primary pressure pulse propagating thereon, so as to form a first subordinate pressure pulse of a compound pressure pulse; and
at least one ring section, generally concentric with said center section, having predetermined second curvature and focusing characteristics associated therewith, and formed to direct the primary pressure pulse propagating thereon, so as to form at least one additional subordinate pressure pulse of said compound pressure pulse.
There is thus also provided, in accordance with the present invention, pressure-pulse therapy apparatus, which includes:
a disk-like acoustic lens, having:
a center section, having predetermined first curvature and focusing characteristics associated therewith, and formed to direct a primary pressure pulse propagating thereon, so as to form a first subordinate pressure pulse of a compound pressure pulse; and
at least one ring section, substantially concentric with said center section, having predetermined second curvature and focusing characteristics associated therewith, and formed to direct a primary pressure pulse propagating thereon, so as to form at least one additional subordinate pressure pulse of said compound pressure pulse;
proximal and distal sides with respect to a tissue for treatment;
an enclosure with an open end;
a flexible diaphragm, which caps said open end;
a fluid medium, contained within said enclosure, for facilitating propagation of the pressure pulses;
a pressure-pulse source, which includes a disk-like, electromagnetic pressure-pulse source, immersed in the medium, located at said distal side of said acoustic lens, for generating a collimated primary pressure pulse that propagates in said medium, and impinges on said acoustic lens; and
a power supply, which supplies power to said pressure-pulse source.
There is thus also provided, in accordance with the present invention, pressure-pulse therapy apparatus, which includes:
a disk-like acoustic lens, having:
a center section, having predetermined first curvature and focusing characteristics associated therewith, and formed to direct a primary pressure pulse propagating thereon, so as to form a first subordinate pressure pulse of a compound pressure pulse; and
at least one ring section, generally concentric with said center section, having predetermined second curvature and focusing characteristics associated therewith, and formed to direct a primary pressure pulse propagating thereon, so as to form at least one additional subordinate pressure pulse of said compound pressure pulse;
proximal and distal sides with respect to a tissue for treatment;
an enclosure with an open end;
a flexible diaphragm, which caps said open end;
a fluid medium, contained within said enclosure, for facilitating propagation of the pressure pulses;
a pressure-pulse source, which includes a disk-like, electromagnetic pressure-pulse source, immersed in the medium, located at said distal side of said acoustic lens, for generating a collimated primary pressure pulse that propagates in said medium, and impinges on said acoustic lens; and
a power supply, which supplies power to said pressure-pulse source.
There is thus also provided, in accordance with the present invention, a pressure-pulse therapy method, which includes:
generating a primary pressure pulse;
propagating the primary pressure pulse in a fluid medium;
employing a disk-like acoustic lens, formed of at least two sections, which include:
a center section, having predetermined first curvature and focusing characteristics associated therewith; and
at least one ring section, having predetermined second curvature and focusing characteristics associated therewith;
focusing a first portion of the primary pressure pulse by the center section, thus forming a first subordinate pressure pulse of a compound pressure pulse; and
focusing at least one additional portion of the primary pressure pulse by the at least one additional ring section, thus forming at least one additional subordinate pressure pulse of said compound pressure pulse.
Additionally, in accordance with the present invention, focusing a first portion of the propagation includes substantially focusing the propagation.
Alternatively, focusing a first portion of the propagation includes generally focusing the propagation.
Additionally, in accordance with the present invention, focusing at least one additional portion of the propagation includes substantially focusing the propagation.
Alternatively, focusing at least one additional portion of the propagation includes generally focusing the propagation.
Additionally, in accordance with the present invention, focusing the first portion of the primary pressure pulse propagation and focusing at least one additional portion of the primary pressure pulse propagation with a phase difference between them.
Further in accordance with the present invention, employing a lens formed of at least two sections includes employing a lens formed of a plurality of sections, having predetermined curvatures and focusing characteristics associated therewith, wherein focusing at least one additional portion of the primary pressure pulse propagation includes focusing a plurality of additional portions of the primary pressure pulse propagation by said plurality of sections, thus forming a plurality of additional subordinate pressure pulses.
Additionally, in accordance with the present invention, said plurality of additional subordinate pressure pulses include predetermined phase differences between them.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more clearly understood from the accompanying detailed description and drawings, in which same number designations are maintained throughout the figures for each element and in which:
FIG. 1 is a schematic representation of pressure-pulse therapy apparatus, in accordance with a preferred embodiment of the present invention;
FIG. 2A is a schematic representation of a parabola;
FIG. 2B is a schematic representation of ellipses;
FIG. 3 is a schematic representation of the specific geometry of a reflector formed of three substantially concentric sections, in accordance with a preferred embodiment of the present invention;
FIG. 4 is a schematic representation of a compound pressure pulse formed of subordinate pulses, as a function of time, in accordance with a preferred embodiment of the present invention;
FIG. 5 is a schematic representation of pressure-pulse therapy apparatus, in accordance with a second embodiment of the present invention;
FIG. 6 is a schematic representation of pressure-pulse therapy apparatus, in accordance with a third embodiment of the present invention;
FIG. 7 is a schematic representation of pressure-pulse therapy apparatus, in accordance with a fourth embodiment of the present invention;
FIG. 8 is a schematic representation of pressure-pulse therapy apparatus, in accordance with a fifth embodiment of the present invention;
FIGS. 9A-9B together schematically represent pressure-pulse therapy apparatus, in accordance with a sixth embodiment of the present invention;
FIG. 10 is a schematic representation of a therapeutic treatment applied to a foot, in accordance with a preferred embodiment of the present invention; and
FIGS. 11A-11D are pictorial representations of pressure-pulse therapy apparatus applying therapeutic treatment, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference is now made to FIG. 1, which schematically illustrates pressure-pulse therapy apparatus 10 , in accordance with a preferred embodiment of the present invention. Pressure-pulse apparatus 10 includes a dome-shaped reflector 12 , defining an x-axis passing through its center, and a point of origin O at its center (vertex). Reflector 12 is formed of three substantially concentric sections having different curvatures: a substantially parabolic center section 14 , a substantially ellipsoid ring section 16 , and a second substantially ellipsoid ring section 18 .
In order to illustrate the implications of this particular geometry, reference is now made to FIGS. 2A and 2B, for a basic review of the important features of a parabola and an ellipse, as they relate to the present invention. The following discussion is based on “Standard Mathematical Tables,” Editor-in-Chief of Mathematics S. M. Selby, The Chemical Rubber Co. (CRC), Eighteenth Edition, pp. 355-356.
FIG. 2A schematically illustrates an x-y coordinate system with point of origin O, and a parabola, L, whose vertex, V coincides with point O, and whose mathematical expression is given by:
y 2 =±4 P x. 1.
The focal point, F, of parabola L is at (P, 0 ).
FIG. 2B schematically illustrates the x-y coordinate system with point of origin O, and two ellipses, M and N.
Generally, an ellipse has two vertices, V 1 and V 2 , major and minor axes, a and b, and a center C. The mathematical expression describing an ellipse with a center located on the x-axis, at some point (h, 0 ), is:
( x−h ) 2 /a 2 +y 2 /b 2 =1, 2.
wherein, when center C coincides with point of origin O, the mathematical expression of the ellipse is x 2 /a 2 +y 2 /b 2 =1.
The ellipse has two focal points, F 1 and F 2 , and the distance from the center to either focal point is given by:
±( a 2 −b 2 ) 1/2 . 3 .
Therefore, F 1 is at:
F 1 =h− ( a 2 −b 2 ) 1/2 , 4 .
while F 2 is at:
F 2 =h+ ( a 2 −b 2 ) 1/2 . 5 .
Reference is now also made to FIG. 3, which schematically illustrates the special geometry of reflector 12 of FIG. 1 . Preferably, a center section, between point O and points A—A is a section of parabola L, with vertex, V, at point O and a curvature described by expression 1 above. The focal point of this section, F, is at (P, 0 ), or,
F=P. 6.
Preferably, a first ring section, between points A—A and B—B, is a section of ellipse M, having a curvature described by the expression:
( x−h 1 ) 2 /a 1 2 +y 2 /b 1 2 =1. 7 .
Thus, a first, or proximal focal point, with respect to the reflector is at:
F 1 1= h 1 −( a 1 2 −b 1 2 ) 1/2 , 8 .
and a second, or distal focal point, with respect to the reflector is at:
F 1 2 =h 1 +( a 1 2 −b 1 2 ) 1/2 . 9 .
In a similar manner, a second ring section, between points B—B and C—C, is a section of ellipse N, having a curvature described by the expression:
( x−h 2 ) 2 /a 2 2 +y 2 /b 2 2 =1. 10 .
Its proximal focal point, with respect to the reflector is at:
F 2 1 =h 2 −( a 2 2 −b 2 2 ) 1/2 , 11 .
and its distal focal point, with respect to the reflector is at:
F 2 2= h 2 +( a 2 2 −b 2 2 ) 1/2 . 12 .
A condition of a preferred embodiment of the present invention, as described in FIG. 3, is that the focal point of the center, parabolic section, F, and the proximal focal points of the ellipsoid ring sections F 1 1 and F 2 1 , coincide, or:
P=F=F 1 1 = F 2 1 , and 13.
P=F=h 1 −( a 1 2 −b 1 2 ) 1/2 =h 2 −( a 2 2 −b 2 2 ) 1/2 . 14 .
Where still additional ellipsoid ring sections are used, the two conditions are extended to the additional rings. When the center section is also ellipsoid, the proximal focal points of all the ellipsoid sections should coincide.
Preferably, the distal focal points F 1 2 and F 2 2 of the two ellipsoid ring sections, are different from each other.
F 1 2 ≠ F 2 2 , 15.
and,
h 1 +( a 1 2 −b 1 2 ) 1/2 ≠h 2 +( a 2 2 −b 2 2 ) 1/2 , 16 .
and similarly, for additional ellipsoid ring sections, when they are used.
Preferably, along ring A—A, the y values and preferably also the first derivatives dy/dx of the center, parabolic section and of the first ellipsoid ring section are substantially the same, and preferably, along ring B—B, the y values and preferably also the first derivatives dy/dx of the first and the second ellipsoid ring sections are substantially the same, so as to avoid points of discontinuities which may cause pressure losses. However this condition is not required for the present invention.
Reference is again made to FIG. 1, where in accordance with a preferred embodiment, the curvature of section 14 is substantially described by expression 1, the curvature of section 16 is substantially described by expression 7, and the curvature of section 18 is substantially described by expression 10. Preferably, the values of P, h 1 , a 1 , b 1 , h 2 , a 2 , and b 2 are selected in a manner that meets the conditions specified by expressions 13-16. Thus, focal point F of substantially parabolic center section 14 and proximal focal points F 1 1 and F 2 1 of substantially ellipsoid ring sections 16 and 18 coincide at a point P, on the x axis, preferably inside dome-shaped reflector 12 . Distal focal point F 1 2 of section 16 and distal focal point F 2 2 of section 18 are at different distances from reflector 12 , on the x axis, preferably within a region for treatment 26 of body tissue. In some preferred embodiments, the parameters of sections 14 , 16 , and 18 , namely, P, h 1 , a 1 , b 1 , h 2 , a 2 , and b 2 are selected in a manner that provides for each first derivative along rings A, B, and C, to have a single value, when calculated from the left and when calculated from the right. In this way, pressure losses due to points of discontinuities will be reduced. In some preferred embodiments, h 1 =a 1 , and substantially ellipsoid ring section 16 is constructed as if its first vertex were at point of origin O. Alternatively or additionally, h 2 =a 2 . In some preferred embodiment of the present invention, sample values for the aforementioned parameters are as follows, P=30; h 1 =30; a 1 =65; b 1 =25; h 2 =35; a 2 =70 b 2 =27.
A pressure-pulse source 24 is located at point P. Source 24 and reflector 12 are arranged in a fluid medium 20 , preferably a liquid, such as an aqueous solution, water or oil, in which the pressure pulses propagate. A flexible diaphragm 22 essentially caps dome-shaped reflector 12 and contains fluid medium 20 within. When conducting therapeutic treatment, flexible diaphragm 22 of apparatus 10 is pressed against region for treatment 26 , so that pressure pulses propagate through diaphragm 22 to region for treatment 26 .
Preferably, pressure-pulse source 24 is a substantially point source. Alternatively, pressure-pulse source 24 is a generally point source. Pressure pulse source 24 may be, for example, a spark discharge source described in U.S. Pat. No. 3,942,531 to Hoff, 1976, whose disclosure is incorporated herein by reference. Alternatively, any spark plug source, electromagnetic source, piezoelectric source, or another known source may be used.
A power supply unit 28 , preferably located outside medium 20 , powers pressure-pulse source 24 , with wires 29 connecting power supply unit 28 to source 24 .
The configuration of FIG. 1 provides for a radially expanding primary pulse 30 , originating from substantially or generally point source 24 , to form a compound of subordinate pulses, as follows:
i. a first subordinate pulse 32 , being a substantially collimated pulse, reflected from substantially parabolic center section 14 ;
ii. a second subordinate pulse 34 , being a substantially focusing pulse, reflected from substantially ellipsoid ring section 16 , toward distal focal point F 1 2 , preferably, within region for treatment 26 ; and
iii a third subordinate pulse 36 , being a substantially focusing pulse, reflected from substantially ellipsoid ring section 18 , toward distal focal point F 2 2 , preferably, within region for treatment 26 .
Additionally, a portion of radially expanding primary pulse 30 will impinge on region for treatment 26 , reaching it even before first subordinate pulse 32 .
Reference is now made to FIG. 4, which schematically illustrates the effect of primary pressure pulse 30 on region for treatment 26 , as a function of time. A portion of radially expanding primary pulse 30 is the first to impinge on region for treatment 26 . However, because of the radial nature of the expansion, its amplitude will be relatively low. Subordinate pulses 32 , 34 , and 36 , reflected from reflector 12 , will impinge on region for treatment 26 a little later, generally at different times, since the paths are different for each subordinate pulse.
Radially expanding portion of primary pressure pulse 30 and collimated first subordinate pulse 32 inherently provide for regional treatment of the tissue. The combined effect of second subordinate pulse 34 and third subordinate pulse 36 , each being directed at a different focal point within region for treatment 26 , enhances the regional effect of the treatment.
In some preferred embodiments, only one substantially ellipsoid ring section, such as substantially ellipsoid ring section 16 is used, and the compound pressure pulse that is formed has only two subordinate pulses. Alternatively, more than two substantially ellipsoid ring sections are used, and the compound pressure pulse that is formed has three or more subordinate pulses.
Reference is now made to FIG. 5, which schematically illustrates pressure-pulse therapy apparatus 100 , in accordance with a second embodiment of the present invention. Pressure-pulse therapy apparatus 100 includes a generally, but not exactly, parabolic center section 114 , having a focal zone P′, generally around point P. Focal zone P′ can be determined as follows: a collimated propagation impinging on generally parabolic center section 114 will be directed as focal zone P′, thus defining focal zone P′. Preferably, focal zone P′ is within the reflector's dome.
Preferably, pressure-pulse therapy apparatus 100 further includes a generally, but not exactly, ellipsoid ring section 116 , having a proximal focal zone F 1 ′, which generally coincides with P′, and a distal focal zone F 2 ′, preferably within region for treatment 26 . Focal zone F 2 ′ can be determined as follows: a radially expanding propagation, originating from substantially or generally point source 24 at a point in the center of focal zone F 1 ′ and impinging on generally ellipsoid ring section 116 , will be directed at focal zone F 2 ′, thus defining focal zone F 2 ′. Similarly, focal zone F 1 ′ can be determined as follows: a radially expanding propagation, originating from a substantially or generally point source (not shown) at a point in the center of focal zone F 2 ′ and impinging on generally ellipsoid ring section 116 , will be directed at focal zone F 1 ′, thus defining focal zone F 1 ′.
Preferably, when a portion of primary pulse 30 impinges on generally parabolic center 114 , it is reflected as a slightly convergent or slightly divergent first subordinate pulse 132 .
Preferably, when a portion of primary pulse 30 impinges on generally ellipsoid ring 116 , it is reflected as a poorly focusing second subordinate pulse 134 , generally directed at zone F 2 ′, preferably within region for treatment 26 , rather than at a point such as F 1 2 of FIG. 1 . In this manner, regional treatment is rendered also by subordinate pulse 134 , reflected from a single, generally ellipsoid ring section.
Reference is now made to FIG. 6, which is a schematic representation of pressure-pulse therapy apparatus 200 , in accordance with a third embodiment of the present invention. Pressure-pulse therapy apparatus 200 includes a dome-shaped reflector 212 formed of two substantially concentric sections having different curvatures: a substantially parabolic center section 214 having a focal point F at point P, and a substantially ellipsoid ring section 216 having a proximal focal point F 1 , at point P, and a distal focal point F 2 . Pressure-pulse source 24 is located on the x-axis, at a point P″, preferably, somewhat closer to reflector 212 than point P. This configuration also provides that a radially expanding primary pulse 30 , originating from pressure-pulse source 24 will impinge on reflector 212 and be reflected by it as a compound pressure pulse of somewhat diffused subordinate pulses: a first subordinate pulse 232 which will be slightly convergent, and a poorly focusing second subordinate pulse 234 , generally directed at a zone F 2 ″, preferably within region for treatment 26 . This configuration, too, provides for a regional treatment of the tissue.
Alternatively, point P″, at which pressure-pulse source 24 is located, is further away from reflector 212 than point P.
Alternatively or additionally, pressure-pulse therapy apparatus 200 includes a linear extendor 213 for varying a distance between pressure-pulse source 24 and reflector 212 , along said x-axis, so as to selectably bring point P″ to coincidence with point P, when desired, to selectably bring point P″ to the right of point P, when desired, and to selectably bring point P″ to the left of point P, when desired.
Alternatively or additionally, reflector 212 is arranged for traveling along the x-axis, with respect to pressure-pulse source 24 , so as to selectably bring point P″ to coincidence with point P, when desired, to selectably bring point P″ to the right of point P, when desired, and to selectably bring point P″ to the left of point P, when desired.
Preferably, traveling along the x-axis includes sliding on a rail or in a channel. Alternatively, travelling along the x-axis includes travelling on a threaded rod. Alternatively, another travelling mechanism may be used.
In some preferred embodiments, center region 14 is also substantially ellipsoid.
In some preferred embodiments, functions other than a parabola and an ellipse and different combinations of functions may be used for the curvature of the substantially concentric sections of the reflector. For example, a linear function may be used.
Reference is now made to FIG. 7, which is a schematic representation of pressure-pulse therapy apparatus 300 , in accordance with a fourth embodiment of the present invention. Pressure-pulse apparatus 300 includes an electromagnetic source 310 , for example, of a type described in U.S. Pat. No. 4,782,821, to Reitter, incorporated herein by reference. Preferably, electromagnetic source 310 is disk-like, and is formed of the following layers:
i. a disk-like coil 324 , having a proximal side 321 and a distal side 323 , with respect to region for treatment 26 , and connected to power supply 28 , via cables 29 ;
ii. a backing 322 , at distal side 323 , on which disk-like coil 324 is arranged;
iii. a conductive membrane 328 , at proximal side 321 ; and
iv an insulating foil 326 , arranged between coil 324 and conductive membrane 328 .
Electromagnetic source 310 is thus arranged for generating a collimated pressure pulse 330 .
Preferably, disk-like electromagnetic source 310 is arranged in fluid medium 20 , with an acoustic lens 312 positioned between source 310 and region for treatment 26 . An enclosure 311 and flexible diaphragm 22 contain fluid medium 20 within. When conducting therapeutic treatment, flexible diaphragm 22 is pressed against region for treatment 26 , so that pressure pulses propagate through diaphragm 22 to region for treatment 26 .
Preferably, acoustic lens 312 is disk-like and is formed of a polymer, or another suitable material. Acoustic lens 312 defines an x-axis passing through its center, and a point of origin O at its center. Acoustic lens 312 is formed of at least two, and preferably more than two acoustic-lens sections, such as first, second and third acoustic-lens sections 314 , 316 , and 318 . These may be substantially or generally focusing lens sections. The shape of each of acoustic-lens sections 314 , 316 , and 318 determines whether collimated pulse 330 , impinging on it, will be directed at a focal point or a general focal zone, and the location of the focal point or zone.
Additionally, given source 310 of collimated pulse 330 , impinging on acoustic-lens sections 314 , 316 , and 318 , and given a focal point or zone that is common to acoustic-lens sections 314 , 316 , and 318 , the thickness of each lens section, the lens material, and the distance between the lens section and the common focal point or zone contribute to time differences among pulses reaching the common focal point or zone. Thus, acoustic pulses, originating from source 310 , but impinging on different lens sections, will reach the common focal point or zone with phase differences.
Preferably, acoustic-lens sections 314 , 316 , and 318 are designed, preferably by numerical analysis, to have predetermined focal points F 314 , F 316 , and F 318 which generally coincide at a focal zone F′, within region for treatment 26 . Alternatively, acoustic-lens sections 314 , 316 , and 318 are designed, preferably by numerical analysis, as somewhat distorted lens sections, having predetermined general focal zones F 314 , F 316 , and F 318 , rather that focal points. Preferably, focal zones F 314 , F 316 , and F 318 generally coincide at focal zone F′, within region for treatment 26 . Alternatively, focal zones F 314 , F 316 , and F 318 are somewhat displaced from each other, but within region for treatment 26 .
Additionally, acoustic-lens sections 314 , 316 , and 318 are further designed, preferably by numerical analysis, so that pulses directed from them will arrive at focal zone F′ with predetermined phase differences of about 0.5-1 microsecond between them.
Preferably, acoustic lens 312 includes at least one cutout section, for example, cutout section A—A, preferably at its center, to allow a portion of collimated primary pulse 330 to pass undisturbed. Thus, at least two acoustic-lens sections of acoustic lens 312 may include at least one cutout section, such as section A—A and at least one additional section such as acoustic lens section 314 .
The configuration described in FIG. 7 provides for a collimated primary pulse 330 , originating from disk-like source 310 , to form a compound of subordinate pulses, which impinge on region for treatment 26 with different phases, as follows:
a. a first pulse 332 , which is the center portion of collimated primary pulse 330 passing through cutout section A—A, and is the earliest pulse to reach region for treatment 26 , having the shortest path;
ii. a pulse 334 , which is a substantially or generally focusing pulse, reflected from lens section 314 , toward F 314 , preferably within focal region F′, and is preferably the second pulse to reach region for treatment 26 , having a path that is only slightly longer than that of pulse 332 ;
iii. a pulse 336 , which is a substantially or generally focusing pulse, reflected from lens section 316 , toward F 316 , preferably within focal region F′, and is preferably the third pulse to reach region for treatment 26 , having a path that is only slightly longer than that of pulse 334 ; and
iv. a pulse 338 , which is a substantially or generally focusing pulse, reflected from lens section 318 , toward F 318 preferably within focal region F′, and is preferably the fourth pulse to reach region for treatment 26 .
In an alternate embodiment, acoustic lens 312 may be formed of cutout section A—A and only one acoustic lens section, such as 314 . Alternatively, two, or four, or more than four acoustic lens sections may be used.
In accordance with an alternate embodiment of the present invention, acoustic lens 312 has no cutout section, and is formed of two or more acoustic lens sections.
Reference is now made to FIG. 8, which schematically illustrates pressure-pulse therapy apparatus 400 , in accordance with a fifth embodiment of the present invention. Pressure-pulse apparatus 400 includes a dome-shaped reflector 412 , defining an x-axis passing through its center, and a point of origin O at its center. Reflector 412 is formed of a plurality of substantially concentric ring sections, for example, four substantially concentric ring sections 414 , 416 , 418 and 420 , having different curvatures.
Preferably, the curvature of each substantially concentric ring section is determined by a numerical calculation, so as to comply with the following two conditions:
i. a pulse, originating from substantially or generally point source 24 at a point P, and expanding in a radial fashion, will be reflected by the ring section so as to impinge on a predetermined zone Z i , within region for treatment 26 , wherein the subscript i denotes a substantially concentric ring section; and
ii. a desired time delay, hence a desired phase difference of about 0.5-1 microsecond, will occur between the pulses reflected from adjacent sections.
Alternatively, the curvature of each substantially concentric ring section is determined by a numerical calculation, so that pulses reflected from adjacent sections will all impinge generally on a same, predetermined zone, yet a desired time delay, hence a desired phase difference of about 0.5-1 microsecond, will occur between pulses reflected from adjacent sections.
The configuration seen in FIG. 8 provides for a radically expanding primary pulse 30 , originating from substantially or generally point source 24 , to form a compound of subordinate pulses, as follows:
i. a pulse 434 , reflected from ring section 414 and having the shortest path, will reach region for treatment 26 first, impinging on zone Z 414 ;
ii. a pulse 436 , reflected from ring section 416 , will reach region for treatment 26 second, impinging on zone Z 416 ;
iii. a pulse 438 , reflected from ring section 418 , will reach region for treatment 26 third, impinging on zone Z 418 ; and
iv. a pulse 440 , reflected from ring section 420 and having the longest path, will reach region for treatment 26 last, impinging on zone Z 420 .
Alternatively, zones Z 414 -Z 420 coincide.
Additionally, a portion of radially expanding primary pulse 30 also impinges upon region for treatment 26 , reaching it even before first reflected pulse 434 .
In accordance with the present embodiment, reflector 412 includes step changes between adjacent substantially concentric ring sections. Alternatively, reflector 412 is constructed with smooth transitions between adjacent substantially concentric ring sections.
Reference is now made to FIGS. 9A-9B, which together schematically represent pressure-pulse therapy apparatus 500 , in accordance with a sixth embodiment of the present invention. Pressure-pulse apparatus 500 includes an electromagnetic source 510 , for example, of a type described in European patent EP 0 369 177 B1, incorporated herein by reference. Preferably, electromagnetic source 510 is cylindrical and includes:
i. a cylindrical backing 522 ;
ii. a coil 524 , arranged on an external side of cylindrical backing 522 ;
iii. an insulating foil 526 , external to coil 524 ; and
iv. a conductive membrane 528 external to insulating foil 526 .
Pressure-pulse apparatus 500 further includes dome-shaped reflector 512 , defining an x-axis passing through its center, and a point of origin O at its center. Dome-shaped reflector 512 has a vertex at point O and is formed of a plurality of substantially concentric ring sections, for example, three substantially concentric ring sections 516 , 518 and 520 , having different curvatures. Each substantially concentric ring section is shaped to a curvature, which may be numerically calculated so as to comply with the conditions described hereinabove, in conjunction with FIG. 8 .
The configuration of FIGS. 9A and 9B provides for a primary pulse 530 , originating from cylindrical source 510 , to form a compound of subordinate pulses, as follows:
i. a pulse 536 , reflected from ring section 516 and having the shortest path, will reach region for treatment 26 first, impinging on zone Z 516 ;
ii. a pulse 538 , reflected from ring section 518 , will reach region for treatment 26 second, impinging on zone Z 518 ; and
iii. a pulse 540 , reflected from ring section 520 and having the longest path, will reach region for treatment 26 last, impinging on zone Z 520 .
Alternatively, zones Z 516 , Z 518 , and Z 520 generally coincide.
In alternate embodiments of the present invention, reflector 512 may be formed of fewer ring sections, or of more ring sections.
In accordance with the present embodiment, reflector 512 includes step changes between adjacent substantially concentric ring sections. Alternatively, reflector 512 is constructed with smooth transitions between adjacent substantially concentric ring sections.
Reference is now made to FIG. 10, which schematically illustrates the application of therapeutic treatment by diaphragm 22 of apparatus 10 to a foot 44 , wherein diaphragm 22 presses against surface tissue of foot 44 , in accordance with a preferred embodiment of the present invention.
Reference is now made to FIGS. 11A-11D, which are pictorial representations of apparatus 10 applying therapeutic treatment to different bodily parts, in accordance with some embodiments of the present invention. FIG. 11A illustrates a situation wherein apparatus 10 applies therapeutic treatment to foot 44 . A support fixture 40 , such as a foot rest, is used to facilitate the positioning of foot 44 against apparatus 10 . Preferably, support fixture 40 is adjustable to support different parts of the body. Preferably, support fixture 40 is removable, so apparatus 10 can be pressed directly against a body when a patient is standing or lying prone. Alternatively, support fixture 40 can be folded in.
FIG. 11B illustrates a situation wherein apparatus 10 applies therapeutic treatment to an elbow 42 , supported by support fixture 40 , preferably adjusted for an elbow.
FIG. 11C illustrates a situation wherein apparatus 10 applies therapeutic treatment to a back of a shoulder 46 . Preferably, support fixture 40 has been removed or folded in, and apparatus 10 is pressed directly against back of shoulder 46 . Preferably, apparatus 10 is arranged for traveling along at least one and preferably a plurality of axes, on means of travel 50 , such as a gantry or a bellows. Preferably, apparatus 10 is also arranged for tilting in at least one and preferably a plurality of angular directions, also by means of travel 50 . Preferably, means of travel 50 provides for easy positioning of apparatus 10 against a body.
FIG. 11D illustrates a situation wherein apparatus 10 applies therapeutic treatment to a shoulder 48 , wherein apparatus 10 is pressed directly against shoulder 48 .
In accordance with some embodiments of the present invention, the therapeutic apparatus is used with no accompanying imaging means, since the treatment is regional in nature. Alternatively, x-ray or sonic means are used. Alternatively, another form of imaging means is used.
In accordance with some embodiments of the present invention, the dome-shaped reflector is formed of generally concentric sections. For example, ellipsoid ring sections 16 and 18 (FIG. 1) may be generally concentric with respect to parabolic center section 14 , so that distal focal points F 1 2 and F 2 2 may cluster around the x-axis, slightly off the x-axis. In such a case, ellipsoid ring sections 16 and 18 may be of the same curvature, or of different curvatures.
Preferably, pressure-pulse source 24 is operable to generate primary pressure pulses in the range between 1000 and 6000 bars. Preferably, the therapeutic apparatus is operable to generate, from the primary pressure pulse, subordinate pressure pulses in the range between 5 and 600 bars.
Preferably, power supply unit 28 is as described in U.S. Pat. No. 5,529,572, to Spector, or in PCT publication WO 93/14720, to Spector, both incorporated herein by reference. Alternatively, another suitable power supply unit may be used.
Preferably, the reflector is formed of a material of good acoustic reflection properties, for example, stainless steel, brass or aluminum. Alternatively, another material may be used.
Preferably, the reflector is supported by a mechanical means.
In general the reflector's diameter is between 5 and 40 centimeters, and preferably, between 10 and 25 centimeters.
The present invention may be used in lithotripsy as a non-invasive technique for pulverizing kidney stones and calculi in the bladder and urethra. Additionally, it may be used for dissolving lipids in cells close to the skin and in the pelvic region. Furthermore, it may be used in orthopedic medicine, for example, as a therapeutic means for any of the following:
i. osteoporosis and the inducement of bone growth;
ii. joining of bone fracture, especially, ununion fractures, i.e., fractures that have failed to unite and heal;
iii. disintegration of calculi in fibers and joints; and
iv. pain relief in the cases of calcific tendinitis of the shoulder joint, tennis elbow, golf elbow, and plantar fasciitis (with and without heel spur).
It will be appreciated by persons skilled in the art that the scope of the present invention is not limited by what has been specifically shown and described hereinabove, merely by way of example. Rather, the scope of the present invention is limited solely by the claims, which follow.
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A pressure-pulse therapy apparatus, including a dome-shaped reflector, at least one ring section, a central x-axis, an open end, a flexible diaphragm capping the open end, a fluid medium within the reflector and diaphragm, a pressure-pulse source immersed in the fluid medium and located on the x-axis for generating a primary pressure pulse, and a power supply for the pressure-pulse source. The reflector includes a center section that has a predetermined first curvature and associated reflective characteristics to reflect the primary pressure pulse to form a first subordinate pressure pulse of a compound pressure pulse. The ring section is substantially concentric with the center section and has a predetermined second curvature and associated reflective characteristics to reflect the primary pressure pulse to form at least one additional subordinate pressure pulse of the compound pressure pulse.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a Continuation-In-Part of application Ser. No. 08/922,173 filed Sep. 2, 1997 now U.S. Pat. No. 6,077,344.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
This invention was made with government support under contract DE-AC05-96OR22464, awarded by the United States Department of Energy to Lockheed Martin Energy Research Corporation, and the United States Government has certain rights in this invention.
FIELD OF THE INVENTION
This invention relates to biaxially textured metal oxide buffer layers on metal substrates. More specifically, the invention relates to a non-vacuum process for depositing films of rare-earth oxides with single orientations on metal substrates.
BACKGROUND OF THE INVENTION
Biaxially textured metal oxide buffer layers on metal substrates are potentially useful in electronic devices where an electronically active layer is deposited on the buffer layer. The electronically active layer may be a superconductor, a semiconductor, or a ferroelectric material.
For example, the next generation of superconducting wire to be used for power transmission lines will have a multi-layer composition. Such deposited conductor systems consist of a metal substrate, buffer layer, and a superconducting layer. The metal substrate, such as Ni, Ag, or Ni alloys, provides flexibility and support for the wire. Metal oxide buffer layers, such as cerium oxide (CeO 2 ), or yttria-stabilized zirconia (YSZ), comprise the next layer and serve as chemical barriers between the metal substrate and the top layer, the high-temperature superconductor.
For a superconducting film to carry a high current, a certain degree of alignment between grains of the superconductor is required. Most preferably, the grains should be aligned both perpendicular to the plane of the substrate (c-axis oriented) and parallel to the plane of the substrate (a-b alignment). To achieve this alignment, high T C superconductors have generally been deposited on (100) oriented single-crystal oxide substrates. However, single-crystal substrates are generally too expensive and have poor mechanical properties. As such, single-crystal substrates are presently unsuitable as practical conductors.
A method to develop practical coated conductors is disclosed in U.S. Pat. No. 5,741,377 ('377) by Goyal et al. This method called RABiTs, short for rolling assisted biaxially textured substrates, uses roll-texturing of metal to form a metallic tape with a {100}<001> cubic structure. However, if the metal is nickel or a nickel alloy, a buffer layer between the metal substrate and the ceramic superconductor is necessary to prevent interdiffusion of the ceramic superconductor and the metal substrate and also to prevent the oxidation of nickel substrate during the deposition of the superconducting layer. Useful buffer layers include cerium oxide, yttrium stabilized zirconia (YSZ), strontium titanium oxide, rare-earth aluminates and various rare-earth oxides.
Conductors based on the RABiTs approach typically consist of a biaxially textured metal substrate, one or more buffer layers (usually oxides), and the superconducting compound YBCO or one of the Bi, Ti, or Hg superconductors. To achieve high critical current densities, it is important that the biaxial orientation be transferred from the substrate to the superconducting material. As stated, a biaxially textured metal substrate can be provided by the method disclosed in the '377 patent.
The purpose of the buffer layers is to transmit the biaxial texture of the metallic substrate to the superconductor and to prevent NiO formation and chemical interactions between the metal substrate and YBa 2 Cu 3 O 7−δ (YBCO). The conventional processes that are currently being used to grow buffer layers on metal substrates and achieve this transfer of texture are vacuum processes such as pulsed laser deposition, sputtering, and electron beam evaporation. Researchers have recently used such techniques to grow biaxially textured YBCO films on metal substrate/buffer layer samples that have yielded critical current densities (J C ) between 700,000 and 10 6 A/cm 2 at 77 K (A. Goyal, et al., “Materials Research Society Spring Meeting, San Francisco, Calif., 1996; X. D. Wu, et al., Appl. Phys. Lett . 67:2397, 1995). One drawback of such vacuum processes is the difficulty of coating long or irregularly shaped substrates, and the long deposition times and relatively high temperatures required.
Another purpose of the buffer layers is to prevent oxidation of the metal substrate (for example NiO, when using Ni). If the Ni begins to oxidize, the resulting NiO will likely to grow in the (111) orientation regardless of the orientation of the Ni (J. V. Cathcart, et al., J. Electrochem. Soc . 116:664, 1969). This (111) NiO orientation adversely affects the growth of biaxially textured layers and will be transferred, despite the substrate's original orientation, to the following layers.
A typical architecture is Ni/CeO 2 /YSZ/CeO 2 /YBCO. The CeO 2 layers are kept thin to avoid cracking and the thicker YSZ layer provides chemical protection. The top layer of CeO 2 is included because the lattice parameter of YSZ does not match that of YBCO very well. The difference is about 5%.
For producing high current YBCO conductors on {100}<001> textured Ni substrates, high quality buffer layers are necessary. Buffer layers such as CeO 2 and YSZ have previously been deposited using pulsed laser ablation, e-beam evaporation, and sputtering. In addition, solution techniques have been used to deposit films of rare-earth aluminates on biaxially textured nickel substrates. However, the rare-earth aluminates had c-axis alignment but have frequently given a mixture of two epitaxies (100)[001] and (100)[011]. This is a structure believed to be unsuitable for growth of high critical current films.
It has been demonstrated that RE 2 O 3 (rare earth oxides) can be grown epitaxially on textured Ni substrates by both reactive evaporation and sol-gel processing techniques. However, the process window for growing RE 2 O 3 films are very narrow. Additionally, some of the rare earth oxides go through a cube to monoclinic phase transition.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a new and improved method for fabricating alloy and laminated structures having epitaxial texture.
It is another object of the invention to provide a method to produce epitaxial superconductors on metal alloys and laminated structures having epitaxial texture.
It is yet another object of the invention to provide a non-vacuum process to produce epitaxial buffer layers on metal substrates.
It is a further object of the invention to provide a process for growing rare-earth zirconium oxide buffer layers with single in-plane epitaxy.
Another object of the invention is to provide an epitaxial textured laminate using rare-earth zirconium oxides.
Still another object of the invention is to provide an epitaxial textured superconducting structure having a J C of greater than 100,000 A/cm 2 at 77 K and self-field.
Yet another object of the invention is to provide a solution process for producing single cube oriented oxide buffer layers.
Still a further object of the invention is to reduce the number of buffer layers in a laminated superconductor structure while retaining a good epitaxial match to YBCO.
These and other objects of the invention are achieved by the subject method and product.
BRIEF DESCRIPTION OF THE DRAWINGS
There are shown in the drawings embodiments of the invention that are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
FIG. 1 is a flow diagram illustrating method steps according to a first embodiment of the invention.
FIG. 2 a is a schematic of a buffer layer architecture having the layers: RE 2 Zr 2 O 7 and a biaxially textured substrate.
FIG. 2 b is a schematic of a buffer layer architecture having the layers: CeO 2 , RE 2 Zr 2 O 7 , and a biaxially textured substrate.
FIG. 2 c is a schematic of a buffer layer architecture having the layers: CeO 2 , YSZ, RE 2 Zr 2 O 7 , and a biaxially textured substrate.
FIG. 3 is a theta-2-theta scan of c-axis oriented La 2 Zr 2 O 7 film on a textured Ni substrate.
FIG. 4 is an omega scan of the Ni (002) reflection (Phi=0)(FWHM=8.06°) of a 500 Å thick La 2 Zr 2 O 7 film on a textured Ni substrate.
FIG. 5 is an omega scan of the Ni (002) reflection (Phi=90)(FWHM=6.64°) of a 500 Å thick La 2 Zr 2 O 7 film on a textured Ni substrate.
FIG. 6 is an omega scan of the La 2 Zr 2 O 7 (004) reflection (FWHM=11.45°) of a 500 Å thick La 2 Zr 2 O 7 film on a textured Ni substrate.
FIG. 7 is an phi scan of the Ni (111) reflection (FWHM=7.52°) of a 500 Å thick La 2 Zr 2 O 7 film on a textured Ni substrate.
FIG. 8 is a phi scan of the La 2 Zr 2 O 7 (222) reflection (FWHM=8.97°) of a 500 Å thick La 2 Zr 2 O 7 film on textured Ni substrate.
FIG. 9 is the La 2 Zr 2 O 7 (222) pole figure of a 500 Å thick La 2 Zr 2 O 7 film on a textured Ni substrate.
FIG. 10 is the resistivity plot for a 3000 Å thick YBCO film grown by a BaF 2 process on CeO 2 (150 Å)/YSZ (2000 Å)/La 2 Zr 2 O 7 (500 Å)/Ni substrate.
FIG. 11 is the field dependence of J C for a 3000 Å thick YBCO film grown by a BaF 2 process on CeO 2 (150 Å)/YSZ (2000 Å)/La 2 Zr 2 O 7 (500 Å)/Ni substrate at 77 K.
FIG. 12 is a schematic of a reel-to-reel continuous dip-coating unit.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a method for depositing single epitaxial films of rare-earth zirconium oxides on metal substrates, according to the present invention, is illustrated. The method comprises preparing a biaxially textured metal substrate, preparing a rare-earth zirconium oxide coating solution, coating the metal substrate with the coating solution, and heat treating the metal substrate and solution to pyrolize the coating solution and to form a rare-earth zirconium oxide on the substrate.
Prepare Substrate
Any method of preparing a biaxially textured metal substrate is acceptable for use with this invention. However, the presently preferred method of preparing the biaxially textured metal substrate is disclosed in U.S. Pat. No. 5,741,377 by Goyal et al., which is incorporated herein by reference. The biaxial texture is achieved, for example, by cold rolling high purity (99.99%) nickel rod in a rolling mill until the length of 20 the rod had been increased by a factor of about 20 (deformation was over 95%). The desired cube texture {100}<001> was developed by recrystallization of the rolled Ni at 800° C. for 60-120 minutes at a pressure less than 10 −7 torr or at 900° C. for 60 minutes in a 4% H 2 /Argon gas mixture. Although pre-annealing of the metal substrate to obtain the desired cube structure prior to deposition of additional layer is presently preferred, this is not required. Other preferred materials include, but are not limited to copper, iron, aluminum, and alloys containing any of the foregoing, including nickel.
Clean Substrate
Prior to coating the metal substrate with the rare-earth zirconium oxide coating solution, the metal substrate is preferably cleaned to remove any organics on the metal substrate. Any method of removing organics from the metal substrate is acceptable for use with this invention. For example, the organics can be removed by methods such as vacuum annealing, electro-polishing, or reverse sputtering. However, the presently preferred method of removing organics from the metal substrate is to ultrasonically clean the metal substrate in a cleaning solution.
Any cleaning solution capable of being used during ultrasonification is acceptable for use with this invention; however, the presently preferred cleaning solution is isopropanol. The invention is not limited as to a particular length of time in which the metal substrate is ultrasonically cleaned so long as the organics are removed from the metal substrate. A preferred range of time is between about 5-60 minutes, and a most preferred length of time is about 60 minutes.
Prepare Solution
Many different methods of preparing a coating solution for use with the invention are known. Three commonly used solution preparation techniques are as follows: (i) sol-gel processes that use metal alkoxide complexes in alcohol solution; (ii) hybrid processes that use chelating agents such as acetylacetonate or diethanolamine to reduce alkoxide reactivity; and (iii) metal-organic decomposition (MOD) techniques that use high-molecular-weight precursors and water-insensitive carboxylates, 2-ethyl-hexanoates, naphthanates, etc. in an organic solvent. Although the coating solution can be prepared using any of these methods, any method capable of producing a coating solution capable of being coated on a metal substrate and subsequently capable of forming a rare-earth zirconium oxide on the substrate is acceptable for use with this invention. Additionally, the coating solution can be prepared using any combination of the three methods discussed above or with any other method that requires solution precursors.
In the presently preferred embodiment of invention, rare-earth and zirconium alkoxide precursors were used in 2-methoxyethanol. The preferred alkoxide being rare-earth methoxyethoxides and zirconium n-propoxide. An illustrative example of the method is as follows. The rare-earth isopropoxides and zirconium n-propoxide are reacted with 2-methoxyethanol under an inert atmosphere. After refluxing, a portion of the solution is removed by distillation. The remaining solution is then cooled and additional 2-methoxyethanol is added. The solution was again refluxed, and further portion of the solution was removed by distillation. The process of dilution, reflux, and distillation is repeated to ensure the complete exchange of the methoxyethoxide ligand for the isopropoxide ligand.
The final concentration of the solution is adjusted to obtain a 0.25 M solution of RE 2 Zr 2 O 7 precursor solution in 2-methoxyethanol. The final coating solutions is prepared by reacting 1 part of a 1.0 molar solution of water in 2-methoxyethanol with cation equivalent of the RE 2 Zr 2 O 7 precursor solution. Hydrolysis was not necessary in some instances.
Applying the Coating Solution to the Metal Substrate
Any method of applying the coating solution to the metal substrate is acceptable for use with this invention. However, two preferred methods of applying the coating solution to the metal substrate are (i) spin coating and (ii) dip coating. For either of the two preferred methods, the metal substrate can be dipped in a controlled atmosphere or in air.
Spin coating involves spinning the metal substrate at high revolutions per minute (RPM), for example approximately 2,000 RPM, applying the solution onto the metal substrate. Equipment capable of spin coating is known in the art as a spinner. For example spinners are used during semiconductor manufacturing to apply photo-resist to semiconductor wafers. However, the invention is not limited as to a particular type of spinner. Any spinner capable of applying a coating solution to the metal substrate is acceptable for use with this invention.
Additionally, so long as coating solution is applied to the metal substrate with the desired thickness and uniformity, the invention is not limited as to any particular process parameters for use with the spinner. In a preferred embodiment of the invention, however, the spinner is operated at about 2000 RPM for a period of about 30 seconds to obtain a continuous coating.
Although any equipment can be used to dip coat the coating solution onto the metal substrate, the preferred equipment is a reel-to-reel dip-coating unit as illustrated in FIG. 12 . The reel-to-reel dip-coating unit 20 includes a pay-out reel 22 , a solution container 24 , pulleys 26 , and a take-up reel 28 . The pay-out reel 22 provides the metal substrate 30 for dipping. The solution container 24 contains the coating solution 32 , and the pulleys 26 direct the metal substrate 30 into the coating solution 32 and onto the take-up reel 28 .
Also included can be a furnace 34 for heat treatment of the metal substrate 30 and coating solution 32 . The furnace 34 is preferably disposed between the solution container 24 and the take-up reel 28 . The take-up reel 28 acts to retrieve the metal substrate 30 after being coated with the coating solution 32 .
The rate at which the metal substrate 30 is withdrawn from the coating solution 32 depends upon the desired thickness and concentration of the coating solution 32 on the metal substrate 30 . As the rate of withdrawal increases, at a given point, depending on the solution and the substrate, the amount of coating solution 32 applied to the metal substrate 30 increases. However, so long as the coating solution 32 is applied to the metal substrate 30 with the desired thickness and consistency, the invention is not limited as to any particular withdrawal rate. In a preferred embodiment of the invention, however, the metal substrate is withdrawn at a rate of about 1-3 m/hour.
Heat Treating
The heat treatment process pyrolyzes the coating solution thereby leaving the rare-earth zirconium oxide remaining on the metal substrate. The enclosure containing the metal substrate is preferably purged with a reducing atmosphere prior to the beginning of the heat treating process. Purging the container prior to heat treatment removes undesirable contaminants from the atmosphere within the enclosure. During the heat treating process, the metal substrate is preferably maintained in a reducing atmosphere to prevent any oxidation of the metal substrate. An inert atmosphere may also be preferably maintained around the metal substrate during cooling. Also, by maintaining the reducing atmosphere around the metal substrate during cooling, oxidation of the metal substrate can be prevented.
The heat treatment process is for a combination of time and temperature sufficient to pyrolyze the coating solution and leaves the desired crystal structure of the rare earth zirconium oxide. Any time and temperature combination sufficient to pyrolyze the coating solution and leave the desired crystal structure of the rare earth zirconium oxide is acceptable for use with the invention. A more detailed discussion as to the preferred temperature ranges for the various rare earth zirconium oxide compounds is included below.
During the heat treatment process, low partial pressures of water and/or oxygen gas can be introduced into the atmosphere surrounding the metal substrate. The addition of water and/or oxygen gas acts as a catalyst for pyrolizing the coating solution at lower temperatures. Thus, the introduction of low partial pressures of water or oxygen gas into the atmosphere advantageously allows for a lower processing temperature.
Hydrogen containing atmospheres are the preferred atmospheres for the heat treatment of the coated substrates, with 4 vol. % hydrogen in argon, helium, or nitrogen the most preferred atmosphere for safety reasons. Mixtures of 2-6 vol. % hydrogen are commonly referred to as “forming gas” and are not generally combustible under most conditions. Carbon monoxide/carbon dioxide mixtures are also commonly used as gaseous reducing agents.
Any furnace capable of producing the desired temperature and time parameters is acceptable for use with this invention. Additionally, any enclosure for the metal substrate capable of preventing contamination of the metal substrate is acceptable for use with this invention. However, the presently preferred enclosure is equipped with gas fixtures for receiving the reducing atmosphere.
An illustrative example of the preferred heat treatment process follows, it is being understood that the practice of the invention is not limited in this manner. The coated metal substrate is placed in a quartz tube equipped with a gas inlet and outlet. A bottled gas mixture containing 4% hydrogen in 96% argon is then allowed to flow into the quartz tube for 20-30 minutes at room temperature. At the same time, the furnace is preheated to the desired temperature. The quartz tube is then introduced into the furnace and heated for a period of approximately one hour. After heating, the metal substrate is quenched to room temperature by removing the quartz tube from the furnace. During quenching the flow of 4% hydrogen in 96% argon gas mixture is maintained.
Structure
The invention provides a buffer layer having a good lattice match with the high-temperature superconducting (HTS) layer. This is preferably accomplished by providing a RE 2 Zr 2 O 7 buffer layer grown using the preferred solution process discussed above. In RE 2 Zr 2 O 7 , with RE=La to Lu, many of these compounds have a cubic pyrochlore structure. This structure may be stable up to the melting point of the composition and therefore a large process window is available. Thus, by using RE 2 Zr 2 O 7 , the lattice parameters can be tailored to match the metal substrate or the HTS layer. RE is defined as one or more rare earth elements, alone or in combination.
Having a good lattice match provides for improved epitaxy of the superconducting layer. For example, the lattice parameter, a o , of the superconducting material YBCO is 3.821 Å, and the lattice parameter of the YSZ buffer layer common used with YBCO is about 3.64 Å. YSZ also has a cubic fluorite structure. However, the cubic fluorite structure and the related cubic pyrochlore phases can also be obtained by adding La and other rare earth elements to ZrO 2 . The pyrochlore phases are an ordered fluorite lattice with a lattice parameter twice that of the fluorite phase. This ordering occurs for the La and the lower mass rare earths and is related to the well-known lanthanide contraction. The lattice parameters of these phases are larger than lattice parameters for YSZ, and this leads to a better lattice match with the YBCO and improved epitaxy of the YBCO.
It is observed that the size of the trivalent rare earth ions decreases as the atomic number increases. This effect reduces the lattice parameters of the rare earth stabilized zirconias. All of the pyrochlore and fluorite phases exist over a range of compositions, but the ranges are more restricted for La and the lower mass rare earths. The lattice parameters of these phases all increase with rare earth content. Importantly, the best matches with YBCO occur when the phases are saturated with La or the rare earth elements. Experimental values for the composition dependence of a o for these phases are summarized in Table I.
TABLE I
Effect of Composition on the Lattice Parameters (a o ) of Cubic
Lanthanum and Rare Earth Fluorites and Pyrochlores (1)
Element
Δa o /Δx (2)
La
0.19
Nd
0.43
Sm
0.39
Eu
0.23
Gd
0.33
Tb
u
Dy
0.23
Ho
0.17
Er
0.17
Tm
u
Yb
0.13
(1) Composition is defined by “x” in RE x Zr 1−x O 2 −x/2.
(2) Assumes both fluorites and pyrochlores have the fluorite structure.
u = unavailable
Table II illustrates the lattice mismatch between rare earth fluorites and pyrochlores and YBCO. The second column indicates the preferred maximum solubility of moles (“x”) of the rare earth in the equation RE x Zr 1−x O 2 −x/2. If x exceeds the number indicated in the second column, the resulting structure may not be stable and therefore can decompose to form a mixture of phases. The maximum values of x were obtained from phase diagrams readily available in the literature. For each rare earth element, ZrO 2 to RE 2 O 3 (0 to 100 mol. %) will be plotted against temperature. At each temperature, the existence of a given phase will be apparent for a given value of x. These diagrams also indicate that the values of x are nearly independent of temperature. The processing ranges for the rare earths are about 600-1455° C. The third column is an indication of the change in a o versus the change in x. The fourth column indicates the lattice parameter, a o , when x=0.5. This provides a structure of RE 0.5 Zr 0.5 O 1.75 , which is equivalent to RE 2 Zr 2 O 7 .
The fifth column indicates the best percentage match of the rare earth fluorite/pyrochlore lattice parameter with the lattice parameter of YBCO using the value of x indicated in column 2. As illustrated, all of the rare earth stabilized zirconias provide a better lattice match with YBCO than does YSZ. Additionally, the. cubic pyrochlore La 0.57 Zr 0.43 O 1.715 is presently the most preferred structure.
TABLE II
Lattice Mismatch Between Rare Earth
Fluorites/Pyrochlores and YBa 2 Cu 3 O 7−δ
Maximum “x” for
Fluorite a o (1)
a o (max)/
Element
Cubic Ln x Zr 1−x O 2 −x/2
Δa o/Δx
for x = .5
a o (YBCO)
La
0.57
0.19
5.403
0.992
Nd
0.60
0.43
5.339
0.986
Sm
0.70
0.39
5.275
0.981
Eu
u
0.23
5.277
u
Gd
0.70
0.33
5.264
0.976
Tb
u
u
u
u
Dy
0.67
0.23
5.21
0.962
Ho
0.56
0.17
5.20
0.954
Er
0.50
0.17
5.19
0.951
Tm
u
u
u
u
Yb
0.67
0.13
5.17
0.951
Lu
u
u
u
u
Y
(commercial stabilized zirconia for
0.941
comparison)
(1) Pyrochlore phases are treated as fluorites with a o = a o /2 (fluorite)
u = unavailable
x was determined using phase diagrams from “Phase Diagrams for Ceramists”, Vols 1-4, The American Ceramic Society, Columbus Ohio (1964-1981)
It is noted that two of the rare earths, Ce and Pr, were omitted from Table II because they exhibit both +3 and +4 valence states. Thermodynamic calculations show that at 1000 K the reaction:
Ce 2 O 3 +1/2O 2 →2CeO 2
occurs if PO 2 exceeds about 10 −6 atmosphere. Data is not available to evaluate the actual decomposition, illustrated by:
Ce 2 Zr 2 O 7 +1/2O 2 →2CeO 2 (solid solution)+2ZrO 2 (solid solution)
but its equilibrium pressure at 1000 K must be greater than 10 −6 atm.
The calculations show that the Pr pyrochlore should be much more stable. At 1000 K the pyrochlore Pr 2 Zr 2 O 7 phase would be expected to be stable at oxygen pressures below about 0.26 atm. Development of buffer layer compound materials based on Pr would be hindered by a lack of phase diagram information.
Partial substitution of Ce +4 for Zr +4 in the pyrochlore (ordered fluorite) phase increases the lattice parameter and therefore could also improve epitaxy. It has been shown that replacing 20% of the Zr +4 in Nd 2 Zr 2 O 7 with Ce +4 increases a o by 0.5%. Thus, substituting Ce +4 into the La pyrochlore phase can therefore produce a nearly perfect lattice match to the YBCO lattice. However, the previously discussed thermodynamic calculations indicate that Pr +4 —Zr +4 substitutions probably would not take place because the Pr +4 would likely reduce to Pr +3 .
Furthermore, two more types of rare earth pyrochlores have a o values favorable for YBCO epitaxy. These compounds are based on SnO 2 and HfO 2 ; however, phase diagram information is not available. Also, the SnO 2 compounds should be less stable than those containing ZrO 2 and HfO 2 .
In addition to providing favorable epitaxial conditions by having a closer match of lattice parameters with the superconducting material, the rare earth zirconates advantageously offer favorable chemical characteristics. When a YSZ buffer layer is used with YBCO, after a given time at the processing temperature, a BaZrO 3 reaction layer begins to form at the interface between the YSZ buffer layer and YBCO because the Ba of YBa 2 Cu 2 O 7 reacts with the Zr of YSZ. However, at least two reasons indicate that growth of the BaZrO 3 reaction layer will be less of a problem with a rare earth stabilized zirconia (RESZ) buffer layer. One reason is that the layer will contain less ZrO 2 by roughly a factor of two. Additionally, pyrochlore compositions are essentially interoxide compounds and therefore have greater thermodynamic stability. Therefore, a YBCO film can be grown directly on RE 2 Zr 2 O 7 without the need for a CeO 2 cap layer although it is possible to still use a CeO 2 cap layer.
EXAMPLE 1
Lanthanum isopropoxide was synthesized using the method of Brown et al. The La 2 Zr 2 O 7 precursor solution was prepared by mixing 0.988 g (3.125 mmole) of lanthanum isopropoxide and 1.462 g (3.125 mmole) of zirconium n-propoxide and reacting the mixture with 50 ml of 2-methoxyethanol under an inert atmosphere. After refluxing for approximately 1 hour, approximately 30 ml of the solvent mixture (isopropanol, n-propanol, and 2-methoxyethanol) was removed by distillation. The flask was allowed to cool, and 50 ml of 2-methoxyethanol was added. This process of reflux, and distillation was repeated to ensure the complete exchange of the methoxyethoxide ligand for the isopropoxide ligand. The final concentration of the solution was adjusted by adding 25 ml of 2-methoxyethanol to obtain a 0.2 M La 2 Zr 2 O 7 precursor solution in 2-methoxyethanol. A partially hydrolyzed solution suitable for spin coating or dip coating was prepared by reacting 1 part of a 1.0 molar solution of water in 2-methoxyethanol per cation equivalent of the RE 2 Zr 2 O 7 precursor solution.
Strips of roll-textured nickel were cleaned by ultrasonification for 30 minutes in isopropanol. The cleaned Ni substrates were annealed at 800-1000° C. for 1-2 hours in a high vacuum furnace to obtain the required cube texture. The coating of the nickel was accomplished using spin coating at 2000 RPM for 40 seconds or dip coating with a withdrawal velocity of 1-3 m/hour. With dip coating, the strip of nickel was typically 1 cm wide and 20 cm long.
The nickel substrates were placed in a quartz tube equipped with a gas inlet and outlet. A bottled gas mixture containing 4% hydrogen in 96% argon was allowed to flow for 20-30 minutes at room temperature. At the same time, a tube furnace was heated to the desired temperature of 600-1200° C. The La 2 Zr 2 O 7 film started to crystallize as a c-axis aligned film at temperatures as low as 800° C. The quartz tube containing the coated substrate was then introduced into the furnace and heated for periods varying from 5 minutes to 1 hour.
After heat treatment, the coated substrate was quenched to room temperature by removing the quartz tube out of the furnace. During this time, a gas mixture of 4% hydrogen and 96% argon was continually flowing through the quartz tube.
Highly crystalline lanthanum zirconium oxide (La 2 Zr 2 O 7 ) film on (100)[001] roll-textured Ni substrates was obtained. The texture of films were analyzed by X-ray diffraction (XRD), and film microstructure was analyzed using scanning electron microscope (SEM), and electron back scatter Kikuchi patterns (EBKP).
As illustrated in FIGS. 2 a , 2 b , and 2 c , a sol-gel grown RE 2 Zr 2 O 7 (rare earth zirconium oxide) buffer layer can be used as a template to grow any electronic material, including high temperature superconductors. The RE 2 Zr 2 O 7 can also be used with (FIG. 2 c ) or without (FIGS. 2 a , 2 b ) a YSZ layer. Also, CeO 2 cap layers can be added (FIGS. 2 b , 2 c ). A roll-textured metal substrate is preferably used as a template; however, any biaxially textured substrate is acceptable for use with this invention.
FIGS. 3-9 illustrate the XRD data for a 500 Å thick sol-gel grown La 2 Zr 2 O 7 film that was heat-treated at 1160° C. in a flowing gas mixture of 4% H 2 and 96% Ar on roll-textured Ni substrate. The strong (400) peak of La 2 Zr 2 O 7 in FIG. 3 indicates the presence of a strong c-axis aligned film. The omega and phi scans of FIGS. 4-8 and La 2 Zr 2 O 7 (222) pole figures of FIG. 9 indicate the presence of a single in-plane textured La 2 Zr 2 O 7 film. Also, the pole figures of FIG. 9 indicate the presence of single cube orientation. A SEM micrograph indicated the presence of a dense and crack-free microstructure.
EXAMPLE 2
Yttria stabilized zirconia (YSZ) films were grown on sol-gel deposited La 2 Zr 2 O 7 /Ni substrate. The La 2 Zr 2 O 7 layer was formed using the method according to the invention. The YSZ film was grown by rf magnetron sputtering.
The sol-gel La 2 Zr 2 O 7 /buffered Ni substrates were mounted on a heating block inside the sputter system. Prior to heating the substrate, the sputter chamber was evacuated to a pressure of about 1×10 −6 Torr. The chamber was then back-filled to a pressure of 10 mTorr with a mixture of 4% H 2 and 96% Ar. The substrate was heated to about 780° C. and annealed at 780° C. for 10 minutes prior to sputtering. After annealing, YSZ was sputter deposited at 780° C. for about 1-2 hours with an on-axis YSZ target located about 5 cm from the substrate. The plasma power was 75 W at 13.56 MHz.
The resulting YSZ film was smooth, epitaxial and dense. The thickness of the YSZ film was estimated to be approximately 2000-3000 Å. A thin (about 150 Å) layer of cerium oxide (CeO 2 ) film was grown on the YSZ/La 2 Zr 2 O 7 /Ni substrate by rf magnetron sputtering. The conditions used were similar to the deposition of the YSZ except for a shorter sputtering time and use of a CeO 2 target. The resulting CeO 2 cap layer was also epitaxial.
EXAMPLE 3
A precursor YBCO film was grown on CeO 2 /YSZ/La 2 Zr 2 O 7 /Ni substrate. The La 2 Zr 2 O 7 layer was formed using the method according to the invention, and the CeO 2 and YSZ layers were formed using sputtering. The YBCO film was grown by electron beam co-evaporation of Y, BaF 2 , and Cu.
The combined deposition rate of the YBCO film was approximately 0.5 nm/sec. During evaporation, the buffer layers were held at approximately 100° C. while the initial pressure of 2×10 −6 Torr rose to 6×10 −6 Torr. Tantalum cruciles were used for the Cu, Y, and BaF 2 sources. Steady BaF 2 evaporation rates were obtained by covering the crucile with a matching lid with a 3-mm orifice. The deposited precursor films were post-annealed in a flowing mixture of N 2 , O 2 , and H 2 O with the partial pressure of O 2 at about 200 mTorr and the partial pressure of H 2 O at about 40 Torr. The post-annealing was at 740° C. for about 60 min. At the end of the post-annealing the gas flow was switched to the dry conditions by reducing the partial pressure of water.
The sample was then cooled to 500° C. for a 30 minute oxidation anneal in one atmosphere of O 2 . The high-temperature anneal under wet conditions resulted in conversion of the Y, BaF 2 , Cu into Yba 2 Cu 3 O 7 −x.
The temperature dependence of the resistivity for an approximately 3000 Å thick YBCO film on CeO 2 /La 2 Zr 2 O 7 /Ni substrates is shown in FIG. 10 . The transition temperature (T C ) obtained was approximately 90 K. FIG. 11 shows the field dependence of J C for a 3000 Å thick YBCO films on CeO 2 /La 2 Zr 2 O 7 /Ni substrates. A high J C of 480,000 A/cm 2 at 77 K and zero field was obtained. As illustrated in FIGS. 10 and 11, the sol-gel deposited La 2 Zr 2 O 7 layer provides a good template.
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A laminate article comprises a substrate and a biaxially textured (RE x A (1−x) ) 2 O 2−(x/2) buffer layer over the substrate, wherein 0<x≦0.70 and RE is selected from the group consisting of La, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu. A is selected from the group consisting of Zr +4 , Ce +4 , Sn +4 , and Hf +4 . The (RE x A (1−x) ) 2 O 2−(x/2) buffer layer can be deposited using sol-gel or metal-organic decomposition. The laminate article can include a layer of YBCO over the (RE x A (1−x) ) 2 O 2−(x/2) buffer layer. A layer of CeO 2 between the YBCO layer and the (RE x A (1−x) ) 2 O 2−(x/2) buffer layer can also be include. Further included can be a layer of YSZ between the CeO 2 layer and the (RE x A (1−x) ) 2 O 2−(x/2) buffer layer. The substrate can be a biaxially textured metal, such as nickel. A method of forming the laminate article is also disclosed.
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FIELD OF THE INVENTION
The present invention relates to toilet cleaning devices which may be concealed within the flush tank of a toilet, and more particularly to a foldable toilet plunger device which may be concealed and attached to the interior surface of a toilet.
BACKGROUND OF THE INVENTION
Toilet plungers and other cleaning devices have long been used to unblock and clean toilet drains. It is preferable to store such devices out of sight, since they are generally unsightly and unsanitary, but such devices are often difficult to store because of the limited amount of space in most bathrooms. Furthermore, the means of storage should securely support the cleaning devices and allow for drainage, yet allow them to be readily available when needed to clean or remove blockages in the drains.
Earlier efforts have attempted to respond to the storage and convenience-of-use problems, providing toilet plunger covers and/or combination toilet plunger covers and toilet plungers. For example, in U.S. Pat. No. 5,114,006 to Wilk, and U.S. Pat. Nos. 5,335,374 and 5,305,880 to Wilk et al., the toilet plunger housing is part of the toilet plunger. The Wilk ('006) combination toilet plunger and housing device has a housing with a slotted base which rests directly on the floor, wherein the plunger cup rests upon the slots when the plunger is in storage, and the same slots are used for grasping of the housing when the plunger is extended for use. Other embodiments of Wilk ('006) disclose the plunger cup resting on a removable base plate when the plunger is in a storage position. The '374 and '880 patents further expand upon this basic concept.
More recently, in U.S. Pat. No. 5,958,150 by Borger et al. disclosed a separate storage device which can be opened and closed without being manipulated directly by the user. The storage device also serves to partially conceal the plunger when closed and allows the plunger to drain while sitting in the device. Both the Borger and Wilk devices are stand-alone assemblies for housing the plunger apart from the toilet.
U.S. Pat. No. 2,701,702 by Deiderich, on the other hand, provides an accessory for use within a toilet flush tank which supplies deodorant or disinfectant and may also support a toilet brush. The accessory is preferably a metal wire apparatus which is supported by the overflow pipe. Thus use of toilet plungers is not disclosed in the '702 patent.
Thus, while there has been substantial effort in the design of bathroom accessory storage devices for toilet plungers and other cleaning devices, the art has not adequately responded to date with the introduction of a means for storing a toilet plunger or other cleaning device which securely stores the toilet plunger or other cleaning device in a concealed fashion that allows for drainage and ready access, while not occupying additional scarce bathroom space or presenting an unattractive visage. The present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
The concealed toilet cleaning system of the present invention provides a system for concealing and storing a toilet plunger within a toilet flush tank to allow for drainage and ready access to the plunger without occupying additional space within the bathroom or risking unsanitary and unsightly exposure to the toilet plunger when the toilet plunger is not in use. Furthermore, the present invention provides a toilet plunger device which can be more readily stored within a toilet flush tank. Additionally, the cleaning system of the present invention provides a method of storing and using a concealed toilet plunger or toilet brush.
Generally a holder is attached to the interior of the toilet flush tank in order to secure the toilet plunger out of sight within the toilet flush tank. The holder retains the plunger or other cleaning device securely so that it does not detach and drop into the toilet flush tank. Preferably, this holder is secured to the cover of the flush tank. Furthermore, in one embodiment, the toilet plunger is fashioned to include a pivot point behind the plunger cup to allow the toilet plunger to be folded so that it is more planar and can be more readily stored close to the surface of the interior of the toilet flush tank. The holder within the toilet flush tank can also be used to secure and conceal other toilet cleaning devices (ex. a toilet brush).
The present invention allows the toilet plunger to be concealed within the flush tank of a typical household toilet, thus allowing any household toilet to be readily converted into a storage device. Through use of a folding toilet plunger, the plunger can be much more readily stored within the toilet flush tank since it less bulky when folded. In particular, when folded it is much more planar and therefore adapted to be closely positioned to the toilet flush tank cover. In addition to preventing unsightly exposure to the toilet plunger, storage within the toilet flush tank is also more sanitary as it prevents contamination of the bathroom by waste material which may accumulate on the plunger cup. Storage within the toilet flush tank also facilitates the drying of the toilet plunger by allowing residual moisture to drain into the lower portion of the toilet flush tank.
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 design of other structures 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
The above and other objects and aspects of the invention will be apparent from the description of embodiments illustrated by the following accompanying drawings:
FIG. 1 is a perspective view of a toilet flush tank where the cover has been lifted to reveal an attached toilet plunger; and
FIG. 2 is a perspective view of a toilet plunger with an elongated handle and pivoting plunger cup.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a concealed toilet cleaning system. Generally, the cleaning system of the present invention includes a toilet cleaning device and a holder 16 for releasably securing the toilet cleaning device to an interior surface of a toilet flush tank 12 . The toilet cleaning device of the present invention normally comprises a handle 24 and a cleaning attachment, such as a plunger cup 26 or a toilet brush (not shown).
A concealable toilet plunger storage system in accordance with an embodiment of the present invention will now be described with reference to FIGS. 1 and 2 . Referring to FIG. 1 , a conventional toilet 10 is shown, focusing on the upper toilet flush tank 12 . Both components are typically made of porcelain, though many other materials with similar properties can be used. The toilet flush tank contains the water reservoir and apparatus necessary to operate the toilet. Toilet flush tanks are typically provided with a toilet flush tank cover 14 which enables easy access to the toilet flush tank for maintenance or other purposes.
An embodiment of the toilet plunger 20 of the present invention is shown in FIG. 1 secured to the bottom surface of the toilet flush tank cover 14 . While it is preferable to secure the toilet plunger to this surface, as this surface provides the most ready access, the use of other surfaces within the toilet flush tank for mounting the toilet plunger 20 are also envisioned, as other surfaces will allow the toilet plunger 20 to be securely stored in an inconspicuous location while allowing drainage and satisfying various other criteria. The typical toilet flush tank 12 contains a flush mechanism and a float device (not shown), which present potential obstacles to the toilet plunger 20 . Thus, it is most preferable to position the toilet plunger 20 so that the plunger cup 26 is positioned over the float device, as there is typically more space available here than over the flush mechanism. Toilets that have anti-siphon ballcock devices rather than a float device will generally have a greater amount of space. When less room is available for the toilet plunger 20 , a light-duty 4″ plunger cup size can be used. As will be described below, the plunger is preferably capable of folding in order to take up less space within the toilet flush tank.
A holder 16 is used to secure the toilet plunger 20 to whatever portion of the toilet flush tank 12 surface is chosen. A wide variety of devices can serve as the holder 16 ; all that is necessary is to be able to attach the holder to the surface of the toilet and then use it to releasably grip the toilet plunger so that it can be positioned within the flush tank but withdrawn for use. The holder may be secured to the surface of the toilet flush tank 12 or the toilet flush tank cover 14 using a variety of adhesives, or other attachment means such as clamps, bolts, or screws Alternately, the holder 16 may be integrated into the surface of the flush tank 12 or flush tank cover 14 at the time of manufacture. In one embodiment, a Velcro® fastener with an adhesive backing may be used, as this allows the holder to be repositioned as needed. Preferably, the holder grips the handle of the plunger using friction and tension. There are a variety of hardware clips, such as roller jaw clips, that can be used to hold the toilet plunger 20 . A preferred holder 16 is a broom clip composed of a semi-rigid plastic or metal.
Referring to FIG. 2 , the toilet plunger 20 can be of a conventional type and is comprised of an elastomeric or resilient plunger cup 26 and an elongated handle 24 having one end attached to or inserted into cup 26 . As previously suggested, the cup 26 is made of an elastomeric or resilient material. Suitable cup materials include, but are not limited to, rubber, neoprene or any elastic polymer. A conventional plunger typically has a 6″ plunger cup and 20″ handle. However, any size cup or handle that can fit within the toilet tank can be utilized in the present invention. The handle 24 is preferably an elongated cylinder or rod, but many other shapes that transmit force and distance the user from the working cup 26 (i.e., function as a handle) can be used. The handle is preferably composed of a rigid material such as acrylic plastic which resists damage from moisture within the flush tank. Other suitable handle materials are metal, fiberglass, or water-resistant wood. Preferably, the handle 24 attaches to the cup 26 by means of a hinge 28 which allows the cup 26 to pivot so that the plane defined by cup 26 is parallel rather than perpendicular to the line formed by the handle 24 . In an alternate embodiment, the hinge 28 may include a locking mechanism to prevent the cup 26 from wobbling while being used. Once folded, the toilet plunger 20 will take up much less space within the toilet flush tank 12 . It is also preferable to sheath the cylindrical handle 24 in a elastomeric or rubber-like grip material 22 which makes it easier to securely hold the toilet plunger. In another embodiment, the handle of the toilet plunger 20 is designed so that it can be collapsed to reduce its length. For example, the plunger handle 24 could be made of several overlapping cylinders capable of telescoping into the outer cylinder for storage within the flush tank 12 .
To use the toilet plunger 20 , the toilet flush tank cover 14 is first lifted to reveal the toilet plunger 20 . The plunger 20 is then removed from its holder 16 , unfolded, and used to unblock the toilet. After use, the toilet plunger 20 is refolded and secured back to the holder 16 and the toilet flush tank cover 14 is replaced on the toilet flush tank 12 . A label, preferably one with a logo and made up of transparent plastic, can be used to designate the toilet as one with a concealed plunger, in order to alert a potential user to the plunger's presence.
Although the preferred embodiments of the 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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The present invention relates to a system for concealing a cleaning device such as a toilet plunger within a toilet flush tank. A modified toilet plunger has been designed to include a hinge so that the plunger cup can pivot on the end of the plunger handle, thereby taking up less space. The folded toilet plunger is secured to the inside of the toilet flush tank by a holder, preferably on the toilet flush tank cover, so that the toilet plunger is readily accessible yet out of sight and will drain into the toilet flush tank after use.
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BACKGROUND OF THE INVENTION
This invention relates to an electrical connector which is capable of being connected in an environment potentially occupied by fluids and/or gases, such as is found within a borehole.
It is very often desirable to establish an electrical connection within an environment such as that present within a borehole. This type of environment, however, usually involves high pressures and temperatures and a combination of fluids, solids and gases as inhabitants, which make the downhole electrical connection very difficult and complex. The existing electrical connectors that have been developed for fluid environments in general, typically utilize a two-part mateable connector, i.e. a male member and a female member with the female member including a receptacle which is adapted to closely receive a portion of the male member. Both the female member and the male member contain one or more electrically conductive elements thereon which establish electrical contact with each other when the male member is inserted into the female member. To enable this connector to operate within a fluid environment a complex arrangement of plungers and pistons is generally used to evacuate the fluid contents of the receptacle, or a dielectric oil is contained within the receptacle to ensure electrical isolation even in the presence of an invading fluid, or the connector uses some combination of the above. The complex configurations which result are generally expensive to manufacture and typically prone to failure.
Any use of such general fluid environment connectors in a borehole environment introduces even further difficulties because of the extreme pressure and temperature conditions which are present within the borehole.
SUMMARY OF THE INVENTION
In view of the aforementioned shortcomings of the connectors described above, the improved connector of the present invention has been designed with a simplified structure that can be utilized to achieve electrical connection in a downhole environment in spite of the severe pressure and temperature conditions found there.
The electrical connector of the present invention comprises two members adapted for mating, i.e. one of the members includes receptacle means for closely receiving at least a part of the other member and the other member includes a projection adapted for insertion within the receptacle means. One of the members also includes a passageway which is in communication with the receptacle means and which affords an egress from the receptacle means through which any fluids within the receptacle means can be displaced as the members are mated. A housing supports one of these members and contains another passageway which is in communication with an environment exterior to the connector and which affords an egress to this exterior environment through which any displaced fluids can be evacuated. Resilient means are interposed between the housing and the member supported by the housing. These resilient means are adapted for closely receiving at least part of the other member, and for sealing the outer periphery of the members from the exterior environment when these members are mated. The resilient means include a third passageway which is in communication with the first passageway and therefore ultimately in communication with the receptacle means. The member supported by the housing is mounted within the housing for movement from a first position where all the passageways are in communication, to a second position where the passageway within the housing and the passageway leading from the receptacle means are not in communication and where the resilient means seal the receptacle means and the electrically conductive elements mated together therein from the exterior environment. The member supported by the housing is normally biased within the housing to the first position affording the egress from the receptacle means to the exterior environment. Any fluids within the receptacle means are therefore displaced through the first, second and third passageways to the exterior environment as the members of the connector are mated. Continued application of a force on the members in the direction of mating and in excess of the force being exerted by the biasing means, affords the movement of the supported member to the second position where the receptacle means and the electrically conductive elements therein are effectively sealed from the exterior environment.
This connector of the present invention therefore evacuates the receptacle in which electrical contact is to be established as the members are being mated and then effectively seals the electrically conductive elements therein from the exterior environment. A connection or disconnection of the connector of the present invention is therefore possible within the extremely hostile environment that is present within the borehole. These advantages of the present invention will be apparent from the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWING
The present invention will be further described hereinafter with reference to the accompanying drawing wherein:
FIG. 1 is a longitudinal sectional view of one of the members of the connector according to the present invention; and
FIG. 2 is a partial longitudinal sectional view of both of the members of the connector according to the present invention with the members mated to establish electrical contact.
DETAILED DESCRIPTION
A first member 12 of the connector 10 according to the present invention is illustrated in FIG. 1. This member 12 would typically be referred to as the female member because it contains a receptacle 14 which is adapted for closely receiving at least a part of the male member 16 (see FIG. 2) of the connector 10. Typically the receptacle 14 of the female member 12 is machined or molded within a solid electrical conductor. Electrically conductive elements could however also be fixed within a receptacle 14 of a female member 12 formed from a non-conductive material. These elements of the member 12 are connected with an appropriate lead 13 to the circuitry with which electrical contact is to be established. For example, the female member 12 of the preferred embodiment is connected to a wireline (not shown) on which this member 12 is lowered into a borehole. Lead 13 is part of this wireline and provides the electrical connection between the female member 12 and the control circuitry that is typically located uphole. Appropriate sealing means 28 are used to seal the entrance of lead 13 into the female member 12.
The corresponding male member 16 is typically part of the sonde or other device (not shown) being used within the borehole to perform measurements on the formations adjacent the borehole. Appropriate electrical connections (not shown) are made between the sonde and the male member 16. The male member 16 has a longitudinal projection 18 thereon which is adapted to be received within the receptacle 14 of member 12 as it is lowered onto the sonde or other device. This projection 18 has one or more electrically conductive elements 20 attached thereto. In the preferred embodiment the male member 16 is very similar to a standard banana plug configuration in which the elements 20 are biased radially outward from the projection 18 to have a greater cross-sectional diameter than the inner diameter of the receptacle 14. Upon insertion of the male member 16 within the female member 12, these elements 20 are compressed thereby ensuring electrical contact with the receptacle 14.
In the preferred embodiment the female member 12 includes a passageway 22 which is in communication with the rear portion of the receptacle 14 and which terminates exterior to the receptacle 14 and adjacent the front opening 15 of the receptacle 14. This passageway 22 affords an egress from the receptacle 14 through which any fluids that might be within the receptacle 14 can be displaced as the members 12 and 16 are mated. It should be mentioned that the passageway described within the female member 12 could also be located within the male member 16 and still function as described.
In the preferred embodiment the female member 12 is supported within a housing 24. To facilitate the assembly of the female member 12 the housing 24 is made up of three separable components 24a, 24b, and 24c which can be joined together in a conventional manner. Alternatively, the male member 16 could also be the supported member. A teflon sleeve 25 is interposed between the housing 24 and the female member 12. This sleeve 25 has two functions, first to electrically insulate certain components of the connector 10 from the exterior environment which may be electrically conductive and secondly to facilitate the sealing action of the connector 10 as will be described. The housing 24 and sleeve 25 include a passageway 26 which is in communication with an environment exterior to the receptacle 14 and which can provide an egress to such exterior environment for any fluids which are displaced from the receptacle 14.
In order to ensure that the borehole fluids cannot invade the receptacle 14 once the members 12 and 16 are mated, eg. by passing between the sleeve 25 and the female member 12 supported therein, a resilient gasket 28 is interposed within the sleeve 25 and between the housing 24 and the female member 12. This resilient gasket or seal 28 is affixed to the female member 12 by the interaction between an annular projection 30 located around the periphery of the female member 12 and a corresponding annular recess 32 located within the resilient seal 28. This resilient seal 28 is closely fitted between the female member 12 and the sleeve 25 in order to seal the female member 12 from the exterior environment. The resilient member 28 also contains a chamber 34 which is adjacent the opening 15 of the female member 12 and therefore in communication with the receptacle 14. The passageway 22 within the female member 12 exits within this chamber 34. The front opening 38 leading into the chamber 34 is adjacent the front end of the resilient seal 28. Also in communication with chamber 34 is a third passageway 36 formed within the resilient seal 28. The female member 12 and the attached resilient seal 28 are normally positioned within the housing 24 such that communication is afforded between the passageways 26 and 36, as well as passageway 22 which also opens into the chamber 34. A spring 29 is positioned within the sleeve 25 between the seal 28 and the housing 24 to bias the female member 12 at this first position. The female member 12, and the resilient seal 28 are however moveable within the housing 24 such that an application of force on the connector 10 in the direction of the mating can overcome the biasing force of the spring 29 and move the female member 12 to a second position within the housing 24 where the passageway 36 within the resilient seal 28 is displaced from the passageway 26 within the housing 24. At this second position the resilient seal 28 effectively seals off all access to the receptacle 14 except through the frontal opening 38 within the resilient seal 28. A conventional releasable latching mechanism (not shown) can be utilized to keep the female member 12 at this second position within the connector 10.
Looking now at FIG. 2, the female member 12 is shown mounted within a section of tubing 39. This tubing 39 is used to further support and protect the member 12 as it is being lowered into the borehole. Also illustrated is the male member 16 which in addition to the projection 18 and electrical contacts 20 includes a plunger 40 and an annular sealing flange 42. This plunger 40 and flange 42 are adapted to cooperate with the resilient seal 28 in sealing the conductive elements 20 from the exterior environment when the members 12 and 16 of the connector 10 are mated. As has already been discussed, the female member 12 is typically attached to a wireline on which it can be lowered into the borehole. The male member 16 is caused to enter the chamber 34. As the female member 12 begins to envelop the male member 16 the longitudinal projection 18 begins to displace any fluid that might be located within the receptacle 14. This fluid is displaced through the first passageway 22 and into the chamber 34 defined by the chamber 34, through the passageway 36 within the resilient seal 28. Since the female member 12 and the resilient seal 28 are initially positioned within the housing 24 such that the passageway 36 is in communication with the passageway 26 and therefore the environment exterior to the connector 10, any fluids within the chamber 34 will be expelled to the exterior environment. When the projection 18 is fully inserted within the female member 12 the annular flange 42 will be in contact with the frontal opening 38 of the resilient seal 28. This frontal opening 38 and the flange 42 are also dimensioned and shaped to ensure a sealed and closely fitting relationshp between the housing 24, the resilient seal 28 and the male member 16. The continued application of force on the members 12 and 16 in the direction of mating moves the female member 12 to its second position where the passageway 26 within the resilient seal 28 is spaced from the passageway 36 within the housing 24. As this happens any path along which fluid could flow is interruped with the resilient seal 28 effectively sealing the conductive elements 20 from the exterior environment. Additionally the relative movement between the tightly fitting resilient seal 28 and the sleeve 25 results in a progressive squeezing or milking action on the seal 28 within the portion of the seal 28 in which the members 12 and 16 are mated. This squeezing action further ensures the evacuation of all fluids within the chamber 34, and therefore the integrity of the electrical connection. Typically the members 12 and 16 are latched at this second position thus ensuring that the respective members are mated together to establish the electrical connection. Numerous releasable latching mechanisms are commercially available and thus will not be described herein.
It is important to mention that this connector 10 can be connected and disconnected in the high pressure conditions present within the downhole environment. This is because the connector is effectively open to the downhole pressure as the connection is made. There are also no chambers containing dielectric or other fluids at atmospheric pressures which must be emptied out against the downhole pressure in order for the connection to be made. Hence this downhole pressure, which is typically several times greater than atmospheric pressure, need not be overcome in order to make the electrical connection.
Having thus described the connector 10 of the present invention it will be understood that changes may be made in the size, shape or configuration of some of the parts of the connector 10 described herein without departing from the present invention as recited in the appended claims. In particular the operative structure of the connector 10, such as the various passageways could alternatively be formed within the male member 16 instead of, or in addition to the female member 12 without affecting the overall performance.
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An electrical connector adapted for making and/or breaking an electrical connection in a fluid environment, having two mateable members forming the electrical connection within an internal receptacle which although open to external environment prior to mating, can be sealed from the external environment as part of the mating process. The connectors includes a passageway leading from the receptacle to the external environment through which any fluids within the receptacle can be expelled as the connection is being made. This passageway is interrupted during the mating process.
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RELATED APPLICATIONS
[0001] This application claims priority to application Ser. No. 61/731,022 filed Nov. 29, 2012 and incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] A. Field of Invention
[0003] This application pertains to a system and method of generating and presenting an exercise regimen to a person that may be based on a prescription by a health professional. The regimen is presented to the person on a display, preferably by an avatar animated using a game engine.
[0004] B. Description of the Prior Art
[0005] Exercising regimens are provided for many people for many reasons, such as a means for promoting recovery after some illness, losing weight, maintaining the person's physical shape, training for an athletic event, and so on. Regimens are typically prescribed by doctors or other health-related professionals, such as physical or occupational therapists, or they can be self-imposed. There are also various audio/visual materials available for demonstrating how to perform exercises. However these materials are generally generic and cannot be customized to the needs of a particular person.
[0006] It is well known that people find in it much more easier to perform exercises, especially consisting of long, tedious regimens, if they could share the activity or do the same activity with another person. That is one of the reasons why gyms and other venues were several people can exercise together have become so popular. However, because each person, especially a person recovering from an illness, has his or her personal needs and requirements, existing exercising sessions at a gym
SUMMARY OF THE INVENTION
[0007] Briefly, this application pertains to a system for providing exercise programs to users based on regimes prepared by health care practitioners. Each regime is automatically converted into a set of exercise sessions, each session consisting of one or more exercises. The exercise sessions are provided to users as audio/video programs. Preferably, an avatar in the video portion of each programs performs the respective exercises and together with the audio portion provides prompts, encourages and instructs the user in following and performing the exercises.
[0008] In order to make the system user friendly, each avatar is custom designed for the users. In addition, elements in each program, including background images, background music, the appearance of avatars, and so on, can be changed from session to session.
[0009] In one embodiment, the movements of the avatars are generated using a game engine. In other words, each exercise for a given exercise session consists of a series of movements for various body parts. These series of movements are provided to the game engine which then generates a video of the respective avatar performing the required movements.
[0010] In one embodiment, a server is provided that receives the regimes and uses libraries to generate avatars and the other elements required for each exercise session. During each session, the user is shown not only the avatar but also various information including historic data related to his performance of the exercise sessions.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a general block diagram of a system for providing exercise programs for a user in accordance with this invention;
[0012] FIG. 2 shows a block diagram for the server of FIG. 1 ;
[0013] FIGS. 3A shows a general flow chart illustrating the process used by the server for generating the exercise program;
[0014] FIG. 3B shows a flow chart for generating the sequence of exercises within an exercise session within the program;
[0015] FIG. 3C shows a general flow chart of how the server delivers an exercise session on demand from a user;
[0016] FIG. 3D shows a flow chart of how the server updates its information at the end of an exercise session;
[0017] FIG. 4 shows a sequence of aural and visual segments that make of a typical exercise session;
[0018] FIG. 5 shows a somewhat diagrammatic representation of how the respective avatar and related information is shown to a user during an exercise session;
[0019] FIG. 6 shows a block diagram of a user device used to obtain an exercise program from the server; and
[0020] FIG. 7 shows a flow chart of the operation of the device of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] In a typical scenario, as shown in FIG. 1 , a user U visits a health care practitioner P who examiners the user and his medical records and based on various factors, describes a regimen R of exercises. This regimen normally consists of several exercises E 1 . . . En. Practitioner P may be a doctor, a physical or occupational therapist, a trainer, etc.
[0022] The practitioner P then, using her PC 200 interacts with an exercise program server 100 through the Internet 300 to generate an exercise program EP based on the prescribed regimen R. The regimen may be generated by the practitioner P electronically on her device 200 . In one embodiment, the practitioner P generates the regime R by first accessing a website associated with server 100 and then filling out the information defining the prescribed regimen. If the user U is an old patient, the practitioner P also associates the exercise program EP with the profile of the user U. If user U is a new patient, the practitioner generates a profile for the user, U and provides other information including avatar information needed to generate a personalized avatar for the user as well as the exercise program ER This information is then used by the server 100 to generate the appropriate exercise program ER As discussed above, the regimen could also be created by a health and exercise trainer working with user U or even by the user U himself.
[0023] Alternatively, the practitioner P generates the regimen R manually (In this latter case, the regimen is transferred to the server in an electronic version at a later time).
[0024] The exercise program EP includes several exercise sessions ES typically to be performed over a period of time, e.g., several months, to be performed one or more times of week.
[0025] After the user visited the practitioner P, he can access the specific exercise program EP tailored for him, through the internet 300 and a permanent user device 400 . Device 400 may be located for example, in the user's home. The device 400 may be associated with a data storage 410 . In one embodiment, the server 100 transmits the whole exercise program to the user device 400 which is then stored in the data storage 410 and the user is then free to interface with the exercise program EP at will, without any further information required from the server 100 . In an alternate embodiment, the individual exercise sessions ES are provided one at a time on demand and are customized as necessary. As will be described in more detail below, each of the sessions ES are stored in the data storage 410 and the user then can access either the latest ES or any of previously received sessions. Alternatively, for example, if he is travelling and is using a temporary access device 500 , instead of providing the whole program EP, the server 100 provides only one of the sessions ES to the user. For example, the user U may be using a laptop as the temporary access device 500 in a hotel room.
[0026] The permanent device 400 is preferably a desktop or laptop based device, although it could also be incorporated into or implemented on a tablet, or even a hand held device. In any event, the user can initiate an exercising session at anytime or place where and when he is ready for it. Thus the device 400 can be used in an office, at home, on the road in a hotel room, a health spa, etc.
[0027] As mentioned above, the device 400 can receive the whole program EP at once, but preferably receives each session separately. More specifically, when the user U is ready for a session, he signs in on server 100 from his device 400 (or 500 ) (preferably through the internet 300 ) that he is ready for a session.
[0028] Preferably, data D is generated by device 400 each time user U is viewing (and presumably performing) an exercise session ES. This data D, includes the time and date the viewing has occurred. This data D is sent back for tracking user U to the practitioner and the server 100 .
[0029] One important feature of the invention is that during each exercising session, the user U is prompted to do each of the particular exercises designated by the respective session. The device 410 includes a display 414 and one or more speakers 416 . Preferably, the prompting is done audio visually by presenting on display 414 an avatar A and playing sounds through one or more speakers 416 . (Temporary device 500 has similar displays and speakers, not shown).
[0030] The process for generating the exercise program EP and its components, the exercise sessions ES is now described. As shown in FIG. 2 , the server 100 includes a microprocessor 12 and several modules that may be implemented by software running on the microprocessor 12 (and stored in a memory 13 ) however individual modules are illustrated herein for the sake of clarity.
[0031] The avatar A is an anatomically correct (preferably human) figure with a head, a body and arms and legs that move to simulate each particular exercise. The avatar could be a generic figure, however, preferably the image of the avatar is customized in order to provide more realism, enhance the quality of the experience, and recreate an environment and experience for the user U (or more than one users) that simulates a sharing between several people or the experience of exercising under the direction of a trainer. For this purpose, a plurality of models for avatars are provided in a model library 14 . The images may include models having different characteristics such, height, weight, skin color, hair color, hair cut, etc. In one embodiment, images may be of well known real or imaginary persons. A clothing library 16 holds images of various articles of clothing to be worn by the avatar. Various colors for the articles of clothing, including well known insignia or brand names may also be included in the clothing library. A background library 18 provides various backgrounds against which the image of the avatar A is presented.
[0032] A music library 20 holds various songs and a sound clip library 22 holds sound clips of instructions and other sounds.
[0033] A text message library 25 holds text messages.
[0034] When the user U is signed up to the system, a preconstructed avatar is either assigned to him or a new avatar is created for him either by practitioner P or some other personnel. For example, as shown in the flow chart of FIG. 3A , in step 600 , the desired avatar characteristics are provided to avatar generator 26 and based on these characteristics a suitable avatar image is selected from the avatar models 14 . For example, if the user U is a female, she may prefer to view an avatar that is also female. In addition, clothing articles and colors are also chosen for the avatar from clothing library 16 . All these characteristics may be constant for all the exercise sessions, or they may change from session to session (or at will) to add to the realistic effects. For example, at the beginning of an exercise session the user may send a message to the server that she wants to change the cloths on the avatar assigned to her. The avatar generator 26 performs the necessary changes and generates a new avatar for the user to be used for that exercise session or a future session (step 604 ). Once the avatar for the user is constructed by generator 26 , in step 602 , the avatar and other parameters and information associated with a specific user U (including his musical preferences, background preferences, etc.) are stored in the profile library 24 (step 606 ). If the user has a profile already, it is retrieved from the profile library 24 as needed.
[0035] A master exercise library 44 is used to store all the exercises that the server 100 can incorporate into an exercise program EP.
[0036] A regimen prescribed by the practitioner P is received by the server 100 and stored in the profile library for each user U (step 608 ). Next, in step 610 , the regimen for user U is used to generate the corresponding exercise program EP with its component exercise sessions ES is generated and stored in EP library 26 . Each exercise called for by regimen R is retreated from the library 44 .
[0037] A typical exercise session, as shown in FIG. 4 includes an audio and a visual component, each component consisting of respective segments. Preferably, the visual component includes a main section which is generally shown at the center of the displays 410 , 510 and one or more sidebars that are arranged around the perimeter of the displays. More specifically, as shown in FIG. 5 , a composite image 530 shown during an exercise session ES may include a main section 532 showing avatar A (with some optional background images that have been omitted for the sake of clarity) and one or two side bars 534 .
[0038] Referring back to FIG. 4 , each session ES starts off with an introduction segment 430 , in which the user U is provided with general information about the session. During this time, text or other visual images are shown in main section 552 (segment 432 ). Next, exercise instructions 440 are provided, preferably accompanied by a visual demonstration segment 442 in which the avatar demonstrates the exercises. Nextm additional pointers such as Do's and Don'ts are provided both audially and visually (segments 450 , 442 ). Finally, the actual exercise segments 460 , 462 are played. During these segments, the avatar is shown performing the respective exercises, while the audio track plays a real time count synchronized with the movement of the avatar. So, for example, if an exercise session includes ten pushups, the avatar performs pushups and each pushup is counted out loud in the sound track. Additional sound clips are also played either in the background (e.g., music) or other messages are played between the counts, including inspirational messages (that may be played at random), additional instructions, and so forth.
[0039] The session ES can be interrupted and resumed at any time.
[0040] Moreover, some of the instructions and messages can be shortened, or eliminated after they have been played several times. For example, if the same sessions ES is being played for the fifth time, the introduction can be eliminated, together with all or some of the exercise instructions or do's and don'ts. The speed at which the exercise is performed can also be changed automatically. For example, initial, the avatar can be performing pushups at a low rate, e.g., 1 per second. if the user is playing the same session ES the fourth time in a week, the rate may be increased to four pushups in three seconds. After 10 sessions, the rate may be increased to 2 pushups per second. The user can optionally change this rate manually. As discussed above, long and short term changes may be made as well. For example, the background images can be changed with each season, the colors of the clothing form the avatar may be changed, the music played may be changed, the music may be changed every time the session is played, etc. In this manner, the user can view (and hopefully participate with) the same exercise session several times and each time the experience will be slightly different to make it a more entertaining and exciting experience for the user. Preferably, these changes are made by the server before the respective session ES is downloaded.
[0041] The sidebar 534 is used to provide additional information during each session, such as the time when the session was started, how long is the session, how much time has elapsed since the session has started, how much is left in the session, how many times an exercise has been repeated, what is the next exercise within the session, what exercises are included in the next session, how many times the user has watched this current session, etc.
[0042] Returning to FIGS. 2 and 3A , after a regimen is stored in step 608 , a director 28 analyzes the regimen, collects the required background images, sound clips, text messages, and puts together the audio and visual tracks for each of the exercise session (illustrated in FIGS. 4 and 5 , step 610 in FIG. 3A ) of the program, and stores them in the user EP library 40 (step 612 ).
[0043] Importantly an avatar movement library 42 is provided which defines a series of movements required to be performed by the avatar A for each exercise. For example, for each pushups, the arms, legs, torso, head and neck of the avatar have to perform certain precise movements. A game engine 30 and an avatar controller use the information from the library 42 to generate video images of the respective avatar performing the respective exercise in real time. This information becomes part of the respective ES and is stored with all the other information into user EP library 40 . Moreover, even for the same ES, some details of the exercise, e.g., the rate at which an exercise is performed by the avatar is changed either automatically or in response to a request/command from user U.
[0044] In one embodiment, the game engine 30 and the director 28 are placed in the user device 400 , 500 and the renderings for avatar's motions are generated there rather than in the server.
[0045] FIG. 3B shows more details for step 612 . More specifically, many exercise sessions consist of a plurality of exercises with the user taking several positions for each exercise and which different exercising addressing different muscles, tissues, joints, etc. For example, one exercise session could include a first set of exercises with the user standing, a second set of exercises with the user lying on his left side and a third set of exercises while the user is lying on his right side. Another exercising session includes a first set of exercises requiring a set of exercising involving a first equioment (e.g., a chin bar), a second set of exercises involving a second equipment (e.g. weight lifting) and so on. The director 28 reviews and categorizes the exercises within each exercise session based on a predetermined criteria, e.g., user position, equipment used, etc. (Step 630 ). Next, the director 28 prioritizes and orders the exercises in a sequence using predetermined rules. For example, the director may order the exercises so that all the exercises on the left side are done, followed by all the exercises on the right side, all the exercises, requiring standing, etc. Alternatively, the director 28 may put all the exercising requiring a chin bar followed by exercising requiring weights, etc. In another alternative embodiment the director 28 may group all the exercises together that are directed at strengthening the arms, followed by exercises for the leg, etc. In yet another embodiment, the director 28 may order the exercises in a manner that does not tire out certain members. So for example, exercises for the arm may be interleaved with exercises for the leg.
[0046] Once the sequence of exercises is set by director 28 , in step 634 the proper avatar movements are calculated for the sequence defined in step 632 . Next, one or more background pictures are obtained (step 636 ), the appropriate songs and sound clips are added (step 638 ) and the resulting exercise session is stored in library 40 . Again, some of the determinations in steps shown in FIG. 3B can be permed by the user devices 400 , 500 . This later configuration is especially desirable if the user desires to change some of the exercise session parameters.
[0047] As shown in FIG. 3C , the exercise program for a user has been determined, the server 100 is ready for operation. Typically, in step 660 the server 100 receives a request for an exercise session ES within exercise program ER The server 100 checks the progress of the user and retrieves the appropriate exercise session (step 662 ). In step 664 the exercise session ES modified, if needed. For example, the exercise program EP may have been initially set up in the summer but the request for the altest ES occurs in the winter. The clothing for the avatar and the background images are changed to reflect that it is winter and not summer.
[0048] Finally in step 666 the requested exercise session is sent to the user U and the practitioner may receive a notification of this matter as well.
[0049] As shown in FIG. 3D , once a user finishes watching any exercise session, the server 100 is notified by device 400 , 500 . The notification may include additional information, such as where was the session viewed, how much of the session was viewed by the user, etc. (step 682 ) In step 684 statistics are generated regarding user U and any other user managed by the server 100 and this information is entered into the profile liberty 24 as well as other databases interested in such statistics.
[0050] Certain milestones can be set within the server and when a user reaches certain milestones, rewards may be awarded to the user (step 688 ). For example, the user may be rewarded with points if he completes the first N sessions in a predetermined time. Information is also sent to the practitioner P so that she can see what is going in with user U. For example, the practitioner may want to know if the user U has not finished some exercise sessions within a predetermined period of time, e.g. 3 weeks.
[0051] FIGS. 6 and 7 provide further detail of the operation of device 400 . In addition to screen 410 and speakers 416 , device 400 further includes a user interface 422 (such as a mouse, a keyboard, etc.), a transceiver 424 exchanging signals, normally with server 100 , a database of downloaded exercise sessions and statistics associated with user U and his performance, and optionally, a game engine 430 as discussed above. When the user U is ready to exercise he initiates the process in step 700 (for example by activating an application on device 400 . In step 702 a dashboard (not shown) is presented to the user U indicating various information and statistics, such as when was the last time he exercised, what was the latest ES he has viewed, etc. The dashboard also includes icons for exercise sessions that have been previously downloaded into database 426 as well as the next ES that is due to be downloaded. In step 704 the user can select either one of the previously loaded ES or chose a new ES. If that is the user's choice, the latest ES is downloaded.
[0052] In step 708 the user is presented with the introduction, explanation, instructions, statistics relevant to the user S. This step includes presenting to the user sections 430 , 440 , 450 . In step 710 the user U initiates a start command indicating that he is ready to go on. In steps 720 and 722 the avatar A starts exercising with accompanying sound clips, prompts, count, etc. During play, the user U can issue commands requesting that the exercise session be terminated, stopped temporarily, slowed down, speeded up, cancelled, etc. (step 724 ). When the session is finished an appropriate command is sent to the server 10 and optionally to practitioner P to indicate the progress of user U, and other information, as discussed, by various conventional means, such as an email.
[0053] In one embodiment, the master exercise library contains a complete contains files of different exercises, each file being generated by recording a person performing the respective exercise using anywhere from one up to 34 or more cameras, digitizing the movements of the person(for example, by recording the movement of the person's limbs, joints, etc.) and recording the movement. The game engine is then used to generate a video of an avatar performing the same movement for the same exercise. Once this library is available, one or more practitioner's P can chose a regime of exercises for one or more users, and the regime for each user can be customized for his or her needs, by choosing the exercises for each regime, the number of times it can be repeated, variations in the repetition rate (e.g., a person can start with 5 sits ups and gradually go 15 sits up in 3 months). Moreover, the practitioner can also modify some of the exercises. So, for example, for a leg lift, the practitioner can chose a “hold period” of 0-10 seconds during which the position of the leg is maintained still up in the air.
[0054] Other parameters may be changed as well. For example, in one embodiment, the practitioner can prescribe whether during an exercise the avatar will hold an arm, a leg, etc, at a predetermined angle of let's say 30-75 degrees. Other parameters associated with specific exercises can be made variable as well. When the practitioner accesses a website associated with server 100 , he can be presented with menus indicating the various exercises available, and for exercises with variable parameters, the practitioner can pick and choose the parameters (optionally with some suggested or recommended values for these parameters).
[0055] One important feature of the invention is that an exercise program may include a calendar option that tracks the days on which the user is expected to exercise, the exercise to be performed during each day (if any), etc. Each time the user U watches a respective exercise session, the system assumes that the user has performed the recommended exercises and the calendar is advanced accordingly (e.g., performing situps 10 times the first week, 12 times the second week, etc.). The practitioner can receive real time feedback and can send a modification to the regime, if the practitioner P feels it is necessary.
[0056] One advantage of the invention is that during the generation of the data for each exercise, each movement can be performed by the live actor, but advantageously, duplicate movements may be eliminated. So, if for an exercise, an actor lifts his right leg and is recorded and then the movement for the left leg is required, the movement for the left leg need not be recorded but can be extrapolated for the avatar from the recording of the right leg. In other words, an exercise regime may require the lifting of the right leg 5 times followed by the lifting of the left leg. The director is configured to automatically obtain the data for the right leg once, extrapolate the movement for the left leg and the loop the data for the right leg first five times, followed by the extrapolated movement of the left leg repeated five times.
[0057] Moreover as part of the sorting process described above, for one session the right leg may be shown as moving first for the first week, and then the left leg is shown as moving first for the second week, and so on. In addition, in order to relieve the monotony, assuming for example, that a user must perform exercises five times a week, during sorting and arranging of the exercises, the avatar can be shown from different angles. So on Monday, in the first scene the avatar may be shown from the left side, on Tuesday from the left side, on Wednesday from the front, etc. For each subsequent scene on each day, the avatar could be shown from different angles as well. The angles are selected originally by the director to illustrate how an exercise is to be performed but can be changed dynamically from day to day, week to week, etc.
[0058] One feature of the invention is that each repetition for each exercise is counted out loud on the audio track to encourage the user and so that the user does not have to do it himself. So, for example, if 15 pushups are required, the avatar takes the initial position for pushups, a “one” is heard on the audio track and the avatar performs the first pushup, then a “two” is heard on the audio track while the avatar is performing a second pushup and so on. Thus each repetition is tagged with a number and the number is announced concurrently with the execution of the exercise by the avatar (and hopefully the user). In this manner, each repetition is tagged with a number and the number is then announced as a count. Of course, the counting is properly synchronized with the speed at which the avatar is performing the exercise. If the avatar is performing pushups fast, the counting is kept up so that it is announced at the same rate.
[0059] Numerous modifications maybe made to this invention without departing from its scope as defined in the appended claims.
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This invention pertains to a system for providing exercise programs to users based on regimes prepared by health care practitioners. Each regime is automatically converted into a set of exercise sessions, each session consisting of one or more exercises. The exercise sessions are provided to users as audio/video programs. Preferably, an avatar in the video portion of each program performs the respective exercises and together with the audio portion provides prompts, encourages and instructs the user in following and performing the exercises.
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CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] The present patent application claims the right of priority under 35 U.S.C. § 119 (a)-(d) of European Patent Application No. 05 002 073.4, filed Feb. 2, 2005.
FIELD OF THE INVENTION
[0002] The present invention concerns the use of arabinoxylans as additive in paper production.
BACKGROUND OF THE INVENTION
[0003] The mechanical properties of paper are influenced by a series of different parameters of a chemical and physical nature. Several theories to explain the tear resistance properties of paper have been suggested, most of which emphasise the special relevance of fibre-fibre bonding. Amongst the most frequently cited is the theory that includes the factors of interfibre bonding force of the bonded surface and the length of the fibre.
[0004] It is generally agreed that the hemicelluloses native to the pulp improves the tear resistance and contributes to the formation of stronger fibre bonding. Depending upon the raw material and the pulping method, these hemicelluloses are modified greatly during pulp preparation and are destroyed to a considerable extent.
[0005] The use of xylans as additive in paper manufacture is known. Thus Naterova et al. (Papir a celuloza, 41, (7-8), V23-V30, 1986) describe the addition of 2% maize xylan to packaging paper. In this way the flexural strength is increased by about 172% by the addition of 2% xylan.
[0006] DE 44 09 372 A1, U.S. Pat. No. 5,810,972 and WO 2004/031477 A1 describe the addition of highly refined birch pulp and Lenzing xylan in the range of 0.005 to 0.14% (WO 2004/031477 A1) or 0.15 to 1.5% (U.S. Pat. No. 5,810,972, DE 44 09 372 A1) to tissue products. A positive effect of the xylans and xylan-rich, highly refined birch pulp on the softness of the tissue product and the behaviour of the paper web on the drying drum is described. The breaking strength was increased by 15 to 73% in the machine way and 17 to 90% transverse to the direction of travel. Allegedly the behaviour of the dry end was positively influence but not reported numerically, but assessed according to the experience of the paper maker.
[0007] In the aforementioned applications the use of xylans from the raw material wood and its secondary product pulp is discussed. In particular, the use of acetyl-4-O-methylglucuronoxylan from deciduous wood and arabino-4-O-methylglucuronoxylan from coniferous wood is cited. The examples on the use of xylans cites Lenzing xylan. This product is obtained by alkaline extraction of beech wood pulp in the viscose process and exhibits only a low degree of polymerisation of about 35.
[0008] Consequently different xylans have been investigated in respect of their attributes for the fibre properties or as paper additive. However, the work cited shows that an improvement in tear length is associated with a deterioration in other strength properties or in an unacceptable deterioration in optical properties.
[0009] There is therefore still the requirement for a cost-effective paper additive that brings about an improvement in paper properties, in particular strength, bulk and optical properties.
SUMMARY OF THE INVENTION
[0010] It has now been surprisingly found that the addition of arabinoxylans to pulp during paper production brings about a significant improvement in paper properties. By the use of arabinoxylan the tear length, the tear resistance and the bulk, i.e., the volume of the paper, is improved. The improvement in the bulk improves both the strength properties and the optical properties of the paper. Surprisingly a significantly greater improvement of the paper properties is achieved in comparison to other xylans such as 4-O-methylglucuronoxylans from deciduous wood or Lenzing xylans.
[0011] In accordance with the present invention, there is provided a method of preparing a modified cellulose pulp comprising contacting,
(i) an arabinoxylan, said arabinoxylan being in a form selected from the group consisting of a concentrated solution comprising arabinoxylan and a suspension comprising arabinoxylan, with (ii) a cellulose pulp.
[0014] In further accordance with the present invention, there is provided a modified cellulose pulp comprising:
cellulose pulp; and 0.1% to 40% by weight of an arabinoxylan, based on the total weight of cellulose pulp and arabinoxylan.
[0017] There is also provided, in accordance with the present invention, an arabinoxylan comprising, on its main chain:
5 to 20% arabinose substituents; and less that 5% 4-O-methylglucuronic acid substituents the percent weights being based on the total weight of the arabinoxylan.
[0020] The subject matter of the invention relates in part to the use of arabinoxylans as additive in paper manufacture.
[0021] The features that characterize the present invention are pointed out with particularity in the claims, which are annexed to and form a part of this disclosure.
[0022] These and other features of the invention, its operating advantages and the specific objects obtained by its use will be more fully understood from the following detailed description and accompanying drawings in which preferred embodiments of the invention are illustrated and described.
[0023] Unless otherwise indicated, all numbers or expressions used in the specification and claims are understood as modified in all instances by the term “about.”
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a graphical representation of plots of tear and tensile strengths of pulp samples treated with arabinoxylan; and
[0025] FIG. 2 is a graphical representation of a plot of specific volume of pulp versus tensile break strength for samples of pulp treated with arabinoxylan.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Suitable arabinoxylans are polysaccharides that are present in, for example, different annual plants and agricultural residues such as oat husks, straw or maize. The arabinoxylans can be obtained by different extraction techniques, e.g., with water, steam or solvents with the aid of the most different of auxiliary chemicals, as well as by enzymatic isolation and purification steps. Preferably alkali-extracted arabinoxylans are used, especially arabinoxylans from oat husks that can be obtained, for example, by extraction of oat husks with aqueous alkali solution, separation of the alkaline extract and subsequent precipitation of the alkaline extract in a precipitation bath of water and a water-miscible organic solvent A, with the alkaline extract not neutralised before precipitation.
[0027] The special feature of the arabinoxylans from oat husks in comparison to xylans from deciduous wood and coniferous wood is that they have a comparably high number of arabinose substituents but not the 4-O-methylglucuronic acids occurring in deciduous and coniferous xylans. In comparison to xylans from pulp such as the Lenzing xylans, the arabinoxylans exhibit a much higher chain length.
[0028] Within the context of the present invention arabinoxylans are understood to be such xylans that bear 5 to 20% (w/w relative to the whole sample), preferably 7 to 15%, most preferably 8 to 13% arabinose substituents in their main chain and less than 5%, preferably less than 2%, most preferably less than 1% 4-O-methylglucuronic acid substituents (chromatographic sugar determination after acid hydrolysis).
[0029] Arabinoxylans that are obtained by extraction of oat husks with aqueous alkaline solution with isolation of an alkaline extract and subsequent precipitation of the alkaline extract in a precipitation bath of water with a water-miscible organic solvent A with the alkaline extract not neutralised before precipitation are particularly preferred. Such arabinoxylans exhibit a chain length of at least 100 also after a possible bleaching stage. Usually the chain lengths of these arabinoxylans lie in the range 120 to 240.
[0030] A further subject matter of the invention is a method for the preparation of cellulose pulps comprised of contact with a concentrated solution or suspension of an arabinoxylan with pulp or stock system that contains pulp.
[0031] In one embodiment of the invention the arabinoxylan solution or suspension is added to the fibre suspension before sheet making. The action of the arabinoxylan is also carried out in combination with other paper chemicals which are added to the fibre before, after or together with the arabinoxylan. In this way the use of arabinoxylan is advantageous for the most different of products in the paper industry.
[0032] Other normal paper chemicals are for example wet-strength agents, fillers, retention agents, fixatives, defoamers, deaerators, sizing agents, optical brighteners and colorants.
[0033] A homogeneous solution or suspension of the arabinoxylan can be achieved, for example, by intense mechanical loading such as stirring, by the effect of temperature or with the help of chemicals, preferably basic chemicals such as alkali or alkaline earth hydroxides, preferably NaOH. The concentration of the arabinoxylan solution or suspension can be varied over a wide range of 0.1 to 40% (w/w). Preferred is the range of 0.1 to 25% (w/w), especially preferred is the range from 0.5% to 10% (w/w).
[0034] The arabinoxylan solution or suspension can be incubated with the pulp and the desired paper auxiliaries and additives in high pulp density (solids content) of up to 20% before the pulp enters the headbox of the paper machine. Then by squeezing out the supernatant solution any unabsorbed chemicals can be used for the next batch.
[0035] In a further embodiment of the invention the pulp is mixed with the additives and the arabinoxylan solution or suspension in any desired sequence in the headbox, that is immediately before entry into the machine for paper production. The addition of the arabinoxylan in the headbox usually achieves better results than the previous incubation with the pulp.
[0036] In a further embodiment of the invention the arabinoxylan solution or suspension is added to the pulp suspension before the refinement of the pulp fibres.
[0037] Usually after achieving the optimal quantities no further increase in strength and bulk is achieved by further increase in the amount of arabinoxylan in a product formulation. The optimal amount is dependent upon which other paper auxiliaries are used in the mass so that that the amount of arabinoxylan used relative to pulp can be in a wide range of 0.1% to 40% (w/w). Preferably, however, an amount between 0.5 and 10% arabinoxylan is used. Usually with the use of paper additives the optimal increase in strength is achieved at even lower arabinoxylan concentration.
[0038] The invention is illustrated but not limited in the following by a number of embodiment examples.
EXAMPLES
[0039] Unless otherwise stated in the following examples the compositions of xylans are given as % w/w relative to the whole sample, determined by chromatographic sugar determination after acid hydrolysis.
Example 1
Of the Invention
[0040] An arabinoxylan from oat husks (9.5% arabinose, <1% 4-O-methylglucuronic acid, DP ca. 160) was dissolved in water with heating with formation of a 5% solution. 20 g coniferous sulfite pulp was suspended in water and treated with the xylan solution in the amounts given in Table 1. For experiments with higher amounts of xylan solution correspondingly lower amounts of water were used in each case for suspension of the pulp. After addition of the xylan suspensions the pulp density was 7.1% in each case. The experimental batches were all incubated for 2 h at 50° C. After incubation the pulp was filtered off through a nutsch.
[0041] The pulp was refined for 2.5 min in a Jokro mill in accordance with ISO 5264-3 and laboratory sheets produced in accordance with ISO 5269-2 (rapid Köthen method). Testing for strength was carried out in accordance with ISO 1974 (DIN EN 21974).
TABLE 1 Amount of arabinoxylan in % (w/w) rel. to pulp Tear length (m) 0 2734 (reference) 7.5 3473 22.5 3935 37.5 4199
[0042] The data in Table 1 show that in comparison with the reference pulp without xylan the pulp treated with arabinoxylan from oat husks exhibited considerably higher strength. The tear lengths increased with increasing xylan amounts. The greatest increase in tear length by addition of arabinoxylan from oat husks is 1465 m.
Example 2
Comparison Example
[0043] A 4-O-methylglucuronoxylan from birch wood (no arabinose side chains, 8.8% molar ratio 4-O-methylglucuronic acid relative to xylose units, determined by 1 H NMR, DP ca. 95) was dissolved in water with heating as 5% solution. 20 g coniferous sulfite pulp was suspended in water and treated with the xylan solution. For experiments with higher amounts of xylan solution correspondingly lower amounts of water were used to suspend the pulp. After addition of the xylan suspensions the pulp density was 7.1% in each case. The experimental batches were each incubated for 2 h at 50° C. After incubation the pulp was filtered off through a nutsch.
[0044] The pulp was refined for 2.5 min in a Jokro mill in accordance with ISO 5264-3 and laboratory sheets produced in accordance with ISO 5269-2 (rapid Köthen method). Testing for strength was carried in accordance with ISO 1974 (DIN EN 21974).
TABLE 2 Amount of 4-O- methylglucuronoxylan in % (w/w) rel. to pulp Tear length (m) 0 2734 (reference) 7.5 2983 22.5 3126 37.5 3189
[0045] The data in Table 2 show that the 4-O-methylglucuronoxylan from birch wood can bring about only a very small increase in strength. The action of this xylan is less that 31% of the action of arabinoxylan from oat husks.
Experiment 3
Comparison Example
[0046] The Lenzing xylan from beech wood pulp (no arabinose side chains, 1% 4-O-methylglucuronic acid, DP ca. 35) was dissolved in water with heating as 5% solution. 20 g coniferous sulfite pulp was suspended in water and treated with the xylan solution. For experiments with higher amounts of xylan solution correspondingly lower amounts of water used to suspend the pulp. After addition of the xylan suspensions the pulp density was 7.1% in each case. The experimental batches were incubated for 2 h at 50° C. After incubation the pulp was filtered off through a nutsch.
[0047] The pulp was refined for 2.5 min in a Jokro mill in accordance with ISO 5264-3 and laboratory sheets produced in accordance with ISO 5269-2 (rapid Köthen method). Testing for strength was carried out in accordance with ISO 1974 (DIN EN 21974).
[0048] The data in Table 3 show that the “Lenzing xylan” from beech wood pulp can bring about only a very small increase in strength. The action of this xylan is less that 36% of the action of arabinoxylan from oat husks.
TABLE 3 Amount of Lenzing xylan in % (w/w) rel. to pulp Tear length (m) 0 2734 (reference) 7.5 3010 22.5 3000 37.5 3260
Example 4
[0049] An arabinoxylan (9.5% arabinose, <1% 4-O-methylglucuronic acid DP ca. 160) from oat husks was dissolved in water with heating as 5% solution. A coniferous sulfite pulp was then refined for 2.5 min. in a Jokro mill in accordance with ISO 5264-3 and laboratory sheets prepared in accordance with ISO 5269-2 (rapid Köthen method). The arabinoxylan solutions were in each case added to the pan which is used for portioning the suspension for the individual laboratory sheets. In each pan 16 g pulp were equalised in each case in a total liquid of 6.67 l with a pulp density of 0.24%. The respective amounts of arabinoxylan solution was added. After 5 min portioning and preparation of the laboratory sheets was carried out. All experiments were carried out at room temperature. Testing for strength was carried out according to ISO1974 (DIN EN 21974).
TABLE 4 Influence of arabinoxylan from oat husks on the tear length of coniferous sulfite pulp. The arabinoxylan treatment took place at a pulp density of 0.24% after refinement of the pulp. Amount of arabinoxylan % (w/w) rel. to pulp Tear length (m) Reference 2830 4.7 3759 9.4 4216 28.1 4031
[0050] The tear length can be improved by more than 1000 m by the addition of arabinoxylan from oat husks compared to the reference. With this method of addition the increases in strength can be achieved with low usage of arabinoxylan.
Example 5
[0051] An arabinoxylan from oat husks (9.5% arabinose, <1% 4-O-methylglucuronic acid DP ca. 160) was dissolved in water with heating as 5% solution. A coniferous sulfite pulp was then refined for 2.5 min. in a Jokro mill in accordance with ISO 5264-3 and laboratory sheets prepared in accordance with ISO 5269-2 (rapid Köthen method). The xylan solutions were in each case added to the pan which is used for portioning the suspension for the individual laboratory sheets. In each pan 16 g pulp were equalised in each case in a total liquid of 6.67 l with a pulp density of 0.24%. A cationic polyamide-epichlorhydrin resin was added as paper auxiliary and stirred into the suspension for 5 min. The dosage of the paper additive corresponded constantly to a charge density of 0.013 meq/g pulp in all experiments carried out. Next the respective arabinoxylan solution was added. After 5 min portioning and preparation of the laboratory sheets was carried out.
[0052] All experiments were carried out at room temperature. Testing for strength was carried out according to ISO1974 (DIN EN 21974).
TABLE 5 Influence of arabinoxylan from oat husks on the tear length of coniferous sulfite pulp with concomitant use of a paper additive. The arabinoxylan treatment took place at a pulp density of 0.24% after refinement of the pulp. Arabinoxylan with paper Amount of xylan additive % (w/w) rel. to pulp Tear length (m) Reference 3944 0.09 3992 0.93 4698 2.3 5486 4.7 5629 7.0 5710 9.4 5728
[0053] The tear length can again be significantly increased by the addition of arabinoxylan compared to the reference. It can be clearly seen from the reference that through the use of the paper additive the strength generally lies at a higher level. In regard to the effect of the arabinoxylan a synergistic effect emerges in the interaction with the paper additive. The increases in the tear length are now up to as much as ca. 1800 m. The higher increases in strength are even effective at lower amounts of arabinoxylan than in the experiments without paper additive.
Example 6
[0054] An arabinoxylan from oat husks (9.5% arabinose, <1% 4-O-methylglucuronic acid, DP ca. 160) was dissolved in water with heating as 5% solution. A beech wood sulfite pulp was then refined for 2.5 min, 5 min, 10 min, 15 min and 20 min in a Jokro mill in accordance with ISO 5264-3 and laboratory sheets were prepared in accordance with ISO 5269-2 (rapid Köthen method). The arabinoxylan solutions at 9.4% (relative to pulp) were in each case added to the pan which is used for portioning the suspension for the individual laboratory sheets. In each pan 16 g pulp were equalised in each case in a total liquid of 6.67 l with a pulp density of 0.24%. 5 Min after addition of the arabinoxylan solution portioning and preparation of the laboratory sheets was carried out. All experiments were carried out at room temperature. Testing for strength was carried out according to ISO1974 (DIN EN 21974). Light scattering coefficients were determined according to Instruction SCAN C 27:76.
[0055] The experiments showed that not only the tensile strength of the pulp was increase by arabinoxylan addition, but also the tear strength. The tear-tensile plot allows combined viewing of the tensile strength and tear strength of all samples from the refinement series ( FIG. 1 , Effect of arabinoxylan from oat husks (9.38% relative to pulp) on the tear-tensile plot of beech sulfite pulp). It is obvious that the samples show clearly better values in both strengths by the addition of the arabinoxylan such that the whole curve is displaced to a higher level.
[0056] The specific volume of the pulp is characterised by the bulk, which is plotted in FIG. 2 against the tensile breaking strength (Effect of arabinoxylan from oat husks (9.38% relative to pulp) on the bulk-tensile plot of beech sulfite pulp). It is clear that the curve for the different points of the degree of refinement is displaced to higher bulk values. In order to produce a product with the desired strength a higher sheet volume can be produced by the addition of the arabinoxylan. The increased bulk leads to an increase in the light scattering coefficients and thus to improved optical properties.
[0057] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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A method of preparing modified cellulose pulp using arabinoxyolans is described. The method involves contacting, (i) an arabinoxylan with (ii) a cellulose pulp. The arabinoxylan of the process is in a form selected from a concentrated solution comprising arabinoxylan or a suspension comprising arabinoxylan. Also described are: a modified cellulose pulp prepared according to the present invention; and a particular arabinoxylan having on its main chain 5 to 20% arabinose substituents, and less than 5% 4-O-methylglucuronic acid substituents, (the percent weights being based on the total weight of the arabinoxylan).
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to the mounting and the connection of flat screen displays such as CRT, LCD, PDP (Plasma Display Monitors) and other flat screen display devices and to the mounting and connection of video interphone monitors used in video interphone systems.
[0003] 2. Description of the Prior Art
[0004] Flat screen display devices such as television receivers, PC displays and monitors are mounted on walls using brackets and holders for attaching the display devices at a distance such as 5 cm˜10 cm (2″˜4″) away from the wall, allowing for a space for the connection of cables and their connectors, such as power, video and audio connectors, to the device. The mounts, holders, fixtures and the cables behind the display device are visible and are non-pleasing to the interiors of apartments or offices were they are installed.
[0005] Display devices such as surface mounted video interphone monitors are firmly attached to the wall surface using screws or other fasteners. Other recess mounted video interphone monitors are attached to a back box (embedded into a wall) for recess mounting the video interphone monitors into the wall. In all such video interphone monitor units the cables are connected to terminals inside the video interphone device and its cover is secured by screws to the device itself or to the back box. The screws holding the device cover or the device itself to the back box are non-pleasing to the interior decoration and are objected by architects and interior designers. Moreover, to remove for servicing any of the prior art flat screen display devices and/or the video interphone monitors call for disconnection of the wires, cable and plugs and the mechanical disassembly of the device from the mounts, holders, fixtures, the wall and/or the back boxes, which is time consuming and cumbersome.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a method and apparatus for attaching flat screen display device, such as CRT, LCD, plasma display, LEDs or other flat screen display devices included in apparatuses such as PC display, data display, graphic display, picture display, television receivers, video monitors, video interphone, video conferencing, video telephone, shopping terminals and a combination thereof, onto walls or other flat surfaces and/or into back boxes, buried into walls or other flat surfaces, without visible mounting screws and/or other visible fixing holder, visible fixtures and/or other visible fasteners.
[0007] Another objects of the present invention is to provide the holder with springy contacts for connecting all the electrical and signal lines to the flat screen display device or the video interphone unit through a reciprocal contacts affixed onto the rear surface of the flat screen display device or of the video interphone unit, thereby enabling the removal or the attaching of the display device or the video interphone unit without the need to connect or disconnect individual wires or connectors to and from the display device or the video interphone unit itself. The resile force of the springy contacts also provide the force for latching the display device to latching hooks for preventing accidental release of the display device from its holder.
[0008] Another object of the present invention is to provide an embedded back box for installation into walls or other flat surfaces and for attaching a retractable holder onto a spring guided mount plate, through a set of springs extended from the holder into the spring guided mount plate, thereby providing for tightly attaching the display unit, by a spring action onto the wall surface, without the use of visible screws or other fasteners and/or visible fixtures.
BRIEF DESCRIPTON OF THE DRAWINGS
[0009] The foregoing and other objects and features of the present invention will become apparent from the following description of preferred embodiments of the invention with reference to the accompanying drawings, in which:
[0010] FIGS. 1A and 2A are perspective views of the mounting of a surface type display device of the preferred embodiment of the invention.
[0011] FIGS. 2A and 2B are perspective views of the mounting of a recess type display device of the preferred embodiment of the invention.
[0012] FIGS. 3A, 3B and 3 C are sectional views showing the latching method of the preferred embodiment, using the springy contact assembly and the latching hooks of the present invention.
[0013] FIGS. 4A and 4B are perspective views of the retractable holder attached to a spring guided mount plate in its pull out and pushed back positions.
[0014] FIGS. 5A, 5B and 5 C are sectional views of the holder with the spring guided mount plate in pull out and pushed back positions and the side and front views of the springs.
[0015] FIGS. 6A and 6B are perspective views of the spring and the spring slot of the spring guided mount plate of FIGS. 5A and 5B .
[0016] FIGS. 7A, 7B and 7 C are exploded view and perspective views of the holder in its pull out and pushed back positions within the recess mounting box.
[0017] FIGS. 8A, 8B , 8 C and 8 D are perspective views of the mounting and the removal steps of a surface type display device of the preferred embodiment.
[0018] FIGS. 9A, 9B and 9 C are perspective views of the mounting steps of a recess type display device of the preferred embodiment.
[0019] FIGS. 10A and 10B are perspective views of a decorative frame surrounding a recess type display device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] FIG. 1A shows a flat screen display 100 S for surface mounting onto a surface mount 2 . A display device in the following description may be flat screen displays such as CRT (cathode ray tube), LCD (liquid crystal display), PDM (plasma display monitor) or LED (light emitting diodes) as used in PC display monitors, or video monitors, or television receivers, or video interphone monitor station, video telephone devices, video conferencing terminals or shopping terminals or other display devices used for displaying data, graphics, pictures and a combination thereof. Surface display device in the following description is a display device 100 S shown in FIG. 1A for mounting onto a wall or other flat surfaces such that its entire body protrudes from the surface. Recess display device in the following description is a display device 100 R shown in FIG. 2A for mounting onto a wall or other flat surfaces such that the rear portion of the display device is buried into a cutout in the surface or into a rear box 6 embedded into the wall or the flat surface with only the front frame and/or the front portion of the display device is protruding from, or aligned with the surface. A wall in the following description may be a wall, pole, partition, framework, skeletal structure, fence, bulkhead or any other flat surface occupied by the display device 100 S or the recess display device 100 R.
[0021] The holder 2 of FIG. 1A including four latching hooks 5 and a springy contact assembly 3 is shown attached to a wall 1 by the screws 2 C through the mounting holes 2 A shown in FIG. 1B . The two sets of three holes 2 B shown on top and under the springy contact assembly 3 , are for mounting the holder onto an electrical box, which is well known as a single or dual gang box. The electrical box (not shown) contains the electrical and signal wires, which are connected to the respective contacts 3 A of the springy contact assembly 3 . At last two electrical springy contacts are needed to provide for one electrical circuit. When the electrical box is not used an electrical pipe or other type of conduit can carry the wires to the springy contact assembly 3 . As shown in FIG. 1B the four sockets 15 of the rear surface 111 R of the display device 100 S or of the display device 100 R of FIG. 2B are complementary to the four hooks 5 of the holders 2 or 2 R and as shown in FIGS. 3A, 3B and 3 C when the display device 100 S with its sockets 15 are aligned with ( FIG. 3A ) and pushed onto the hooks 5 ( FIG. 5B ) and slide downwards ( FIG. 5C ), the bosses or convexes 15 A inside the sockets 15 will lock the display device into the latches 5 A of the hooks 5 . The bosses or bars 15 A are shown as semi circled convexes but can be formed into shapes such as rectangular or triangle or any other matching shapes corresponding to the latches 5 A of the hooks 5 .
[0022] The expanded springy contacts 3 A of the contacts assembly 3 of FIG. 3A , are shown compressed 3 AA in FIG. 3B and engage a set of complementary contacts 13 A (shown in FIG. 3C ), assembled or embedded onto the rear surface 111 R of the display device 100 S or 100 R. The compressed contacts 3 AA shown in FIG. 3C force the entire display device 100 S or 100 R away from the holder 2 , thereby firmly securing the convexes 15 A of the sockets 15 to the latches 5 A of the hooks 5 for preventing accidental release of the display device 100 S or 100 R from the holder 2 .
[0023] The contacts 13 A of the preferred embodiment are plated surfaces of a copper pattern of a printed circuit board 14 mounted on the inner side of the rear cover 111 of the display devices 100 S and 100 R and are accessed through a cutout 111 C for accommodating the size and thickness of the contacts assembly 3 . However different types of fixed mounted or embedded electrical contacts can be used instead.
[0024] The springy contacts 3 A, the hooks 5 and the sockets 15 are all shown extended vertically, with the hooks directed upwards for attaching the display devices 100 S or 100 R by mounting the sockets 15 onto the hooks 5 and by pushing the display device against the springy contacts 3 A and for locking the display device to the holder 2 by sliding the display device downward such that the convexes 15 A are latched by the latches 5 A of the hooks 5 . However it is obviously possible to extend the springy contacts 3 A, the hooks 5 and the sockets 15 A vertically in the opposite direction (upside down) thereby latching the display devices 100 S or 100 R to the holder by sliding it upwards. It is similarly possible to extend the sockets 15 , the springy contacts assembly 3 and the hooks 5 sideways to the left or the right thereby latching the display devices sideways to the left or right. Such sideways or upward latching provides for engaging the springy contacts 3 A with the complementary contacts 13 A and for securing the display devices 100 S or 100 R to the holders 2 or 2 R, similarly to the process shown in FIGS. 3A, 3B and 3 C, but in opposite direction (upwards) or left-right direction (sideway).
[0025] Similarly, it is becoming clear that the springy contacts 3 A provide the electrical and signal interconnection between the holders 2 or 2 R and the display devices 100 S or 100 R and the resile force for securing the convexes 15 A of the display device 100 S or 100 R to the latches 5 A of the hooks 5 of the holders 2 or 2 R.
[0026] Though the shown preferred embodiment of FIGS. 1A and 1B include four hooks 5 , four sockets 15 and a single contacts assembly 3 , it is similarly possible to employ two hooks 5 , for example around the vertical center of the holder 2 and extend two contacts assembly 3 one the top and the other on the bottom of the holder 2 (not shown), or it is possible to employ three or six hooks 5 and any number of contact assemblies 3 , to accommodate a variety of display device sizes, shapes, weight and structure, by providing complementary contacts 13 A and sockets 15 on a rear surface of corresponding display devices.
[0027] FIGS. 2A and 2B show a recess display device 100 R, which is similar to the surface display device 100 S of FIGS. 1A and 1B with the exception of the rim or frame 113 surrounding the front cover 112 of the display device 100 R. The rim 113 , as will be explained later, should be tightly forced onto the wall 1 and cover the mounting box and its surrounding edges. Otherwise, the retractable holder 2 R shown in FIGS. 2A and 2B is similar to the holder 2 of the FIGS. 1A and 1B with the exception of the semi circled hooks 2 H for attaching the retractable holder 2 R to the spring guide plate 20 shown in FIG. 4A through four springs 21 , instead of the holder 2 that is attached to a wall 1 using the screws 2 C through the holes 2 A. The mounting steps of the recess display device 100 R onto the retractable holder 2 R are same as the mounting steps of the surfaced display device 100 S onto the holder 2 .
[0028] Shown in FIG. 4A is the retractable holder 2 R supported by four extended springs 21 that are attached to the retractable holder 2 R by four semi circled hooks 2 H at the rear surface 2 RR of the retractable holder 2 R. The springs 21 comprising coil portion 21 C and two expanded arms 21 A, each terminated with a stopper 21 S. The semi circled hooks 2 H for attaching the coil 21 C of the spring 21 provide free rotation to the spring 21 around the axis 2 HA of the semi circle as shown in FIG. 6A . The two arms 21 A of each of the four springs 21 are supported by four slots 23 of the spring guide plate 20 shown in FIGS. 4A, 4B , 5 A, 5 B, 6 A and 6 B. The spring guide plate 20 is attached to the recess mounting box 6 of FIG. 7A using four screws 25 to become the fixed supporting fixture for the retractable holder 2 R, which can be pulled out or pushed back into the mounting box 6 through the four extended springs 21 shown in FIGS. 7B and 7C . The cutouts 23 A in the spring guide plate 20 shown in FIG. 7A are provided for simplifying the assembly of the springs 21 into the slots 23 .
[0029] The recess mounting box 6 of FIG. 2A is shown embedded into the wall 1 with its rim 12 aligned with the wall surface. In practice however embedded or buried mounting boxes are not perfectly aligned with the walls, nor are they perfectly leveled. The exploded view of the box 6 and the spring guide plate 20 shown in FIG. 7A illustrates how the level of the spring guide plate 20 can be adjusted through the angled oval shaped screw holes 22 , which provide for correction of the holder levelness of up to several degrees, such as ±3° by adjusting the spring guide plate 20 inside (a non leveled) embedded box 6 , using the locking screws 25 , also shown in FIGS. 6A and 6B , to lock the spring guide plate into its adjusted position. While the mounting box 6 should not be installed protruding out from the wall surface 1 , the box 6 is commonly installed buried inside the wall, with its rim 12 imperfectly aligned with the wall surface 1 . To compensate for the non evenness of the box 6 with the wall surface 1 , the four springs 21 extended between the retractable holder 2 R and the spring guide plate 20 provide the needed flexible attachment method of the display device 100 R to the wall surface 1 , without the use of any visible screws, fasteners or fixtures.
[0030] The coil 21 C of the spring 21 of FIG. 5C , shown fully recoiled, is supported by the semi circle hook 2 H at the back 2 RR of the retractable holder 2 R and as explained above the semi circle hook 2 H provides free movement to the spring 21 around the axis 2 HA of the semi circle plane. By such movement the spring 21 can be drawn out from the slot 23 to almost perpendicular position versus the holder 2 R, as shown in FIG. 5A and FIG. 6A , or can be pushed back into almost parallel position with the retractable holder 2 R as shown in FIG. 5B and FIG. 6B . The spring 21 of the preferred embodiment is shown made of round wire spring with a coil 21 C portion, but it can be made of flat or round wire spring without a coil, and it can be supported by a different hook (not shown) instead of the semi circled hook 24 , or for example it can be attached to the retractable holder 2 R by a hinge (not shown) or other rotating joints for providing free rotation to the spring in its retracting movement.
[0031] Because the spring 21 is pulled and pushed back through a narrow vertical slot 23 it is preferred to shape the front view of the spring into a curve 28 as shown in the front view 21 F of FIG. 5C and the perspective view shown in FIG. 6A , allowing for a smooth movement of the spring 21 through the slot 23 . The curve 28 also enables the spring 21 to smoothly slip or slide back into the space between the spring guide plate 20 and the recess mounting box 6 and as will be explained later, the curved arms 21 A increase the holding force of the retractable holder 2 R in its pushed back position.
[0032] During the retractable holder 2 R pull out movement it pulls with it the spring 21 by compressing the coil 21 C as shown in FIG. 5A and FIG. 6A all the way until the stopper 21 S engages the slot 23 for preventing accidental removal of the springs 21 from the spring guide plate 20 .
[0033] When the retractable holder 2 R is fully pulled out the arms 21 A of the four springs 21 are bend backward and are forced tightly by the spring recoiling force against the outer 26 edges of the slot 23 as shown in FIG. 4A and FIG. 7B . Pushing back or thrusting the retractable holder 2 R toward the spring guide plate 20 thrusts and slip the arms 21 A inwards 29 through the slots 23 and releases the combined recoiling forces of all the four springs 21 by engaging the released arms 21 A forced against the inner 29 edges of the slots 23 , and creating an escalating force that snaps the retractable holder 2 R inwards into the mounting box 6 until the rim or frame 113 of the display device 100 R is intercepted by the wall 1 shown in FIG. 9C or until the retractable holder 2 R is stopped by the spring guide plate 20 shown in FIGS. 4B, 5B , 6 B and 7 C. Once the springs 21 are slide back into the space between the spring guide plate 20 and the rear of the box 6 , the curved arms 21 A that are pressured against the rear of the box 6 provide added clutching power to the retractable holder 2 R in its push back position, as shown in FIG. 5B .
[0034] The recoiling power can be calculated to provide sufficient clutching force, to accommodate the display device 100 R size, weight and shape. This can be achieved by using different spring wire diameter, or by selecting the spring material hardness and elasticity. Further the retractable holder 2 R is shown as having four springs 21 , but it can be attached using only two springs, one on the left and one on the right side of the display device 21 .
[0035] Alternatively, two springs 21 can attach the retractable holder 2 R one on the top and one at the bottom of the retractable holder 2 R through a corresponding slots 23 one on the top and one on the bottom of a spring guide plate (not shown). It is similarly possible to provide, for example, in addition to the four springs 21 shown in FIG. 4A , four more springs 21 , two on the top and two at the bottom of the retractable holder 2 R. This of course by providing additional appropriate slots 23 on the top and the bottom of a spring guide plate (not shown). Therefore, it is also possible for example, in addition to calculating the spring 21 recoiling power and force to increase the number of the springs, each with lower recoiling power or use lesser number but more powerful springs whenever higher holding force is necessary. Or reduce both the number of and the recoiling power of the springs whenever lower holding force is needed.
[0036] Another important compression force and power calculation is the consideration for attaching and releasing the display device 100 R from the retractable holder 2 R. As explained above the first push back of the display device 100 R toward the mounting box 6 for attaching (or releasing) the display device onto (or from) the retractable holder 2 R is to overcome the resile pressure of the springy contact assembly 3 for releasing the convexes 15 A from the latching hooks 5 . Accordingly, the force to overcome the pressure of the springy contact assembly 3 should be less than the force required to slip back the springs 21 through the slots 23 or the force needed to overcome the clutching of the springs 21 onto the outer surface 26 of the slots 23 edges, holding the holder 2 R in its pulled out position shown in FIG. 4A and FIG. 7B . The difference in the forces enables the push back of the display device 100 R onto the retractable holder 2 R for attachment (or release) while the retractable holder 2 R is in pulled out position. However, it may also be possible to provide a stopper (not shown) for holding the retractable holder 2 R in its pulled out position while attaching or removing the display device 100 R.
[0037] Shown in FIGS. 8A and 8B are the two steps to attach a surface display device 100 S onto the holder 2 , mounted onto a wall 1 . The first step shown in FIG. 8A is to align the sockets 15 of the display device 100 S shown in FIG. 1B and step two is to mount the display device 100 S and push it onto the holder 2 and slide it downwards as shown in FIG. 8B . By this the display device 100 S is latched into place by its convexes 15 A and the latches 5 A of the hooks 5 and its electrical and signal inter connections are engaged through the springy contacts 3 A and the complementary contacts 13 A.
[0038] The steps to remove the display device 100 S from its holder 2 are as simple, with the first step shown in FIG. 8C is to push back the display 100 S toward the wall for releasing the convexes 15 A from the latches 5 A and sliding the display device upwards.
[0039] The releasing step of the display device is another very important item of the invention. Over simplicity of a releasing step may result in accidental release and eventual damage to the display device.
[0040] For this reason, the plurality of the latches 5 A of the hooks 5 and the complementary convexes 15 A of the sockets 15 , offer the safety needed against accidental release, whereby all the convexes 15 A must be released from all the latches 5 A simultaneously, otherwise the upward lifting of the device will be prevented by any one of the latches 5 A. Therefore as shown in FIG. 8C the entire display device 100 S must be pushed toward the wall 1 in order to release all the convexes 15 A from all the four latches 5 A and only then can the display be removed from the hooks 5 and pulled out as shown in FIG. 8D , thereby ensuring no accidental release will take place.
[0041] Shown in FIG. 9A is the first, aligning step, for attaching a recess display device 100 R onto the retractable holder 2 R, having its four sockets 15 aligned with the hooks 5 of the retractable holder 2 R that is clutched in its pull out position, pulled all the way out from the spring guide holder 20 which is attached to the recess mounting box 6 by the screws 25 . The retractable holder 2 R is clutched in its fully pull out position by the four springs 21 as explained above.
[0042] Similar to the attaching of the display device 100 S detailed above, the next step to attach the display device 100 R is to push the display device 100 R onto the retractable holder 2 R and slide it downward for locking the convexes 15 A of the sockets 15 to the latches 5 A of the hooks 5 , as shown in FIG. 9B .
[0043] The final step shown in FIG. 9C is the pushing back of the display device 100 R onto the wall 1 and into the box 6 , and as explained above until the rim or frame 113 is engaged by the wall 1 and the springs 21 are tightly forcing the rim 113 of the display device 100 R against the wall 1 .
[0044] To release and remove the display device 100 R from the retractable holder 2 R calls first for the pulling out of the display device (attached to the retractable holder 2 R) from the mounting box 6 (not shown) and then repeating the steps of pushing the display device toward the retractable holder 2 R and sliding it upwards similar to the display device 100 S shown in FIGS. 8C and 8D .
[0045] The rim or frame 113 , shown touching the wall 1 directly, covers the rim 12 of the box 6 . Commonly the immediate surfaces surrounding a recessed mounting boxes, such as box 6 , are not perfectly finished and therefore it is preferable to provide wide rim or frame 113 to cover all such imperfectly finished surfaces in the vicinity of the rim 12 of the box 6 . Alternatively it is possible to provide a separate decorative frame 213 for fixedly attaching it by screws 6 D into the threaded screw holes 6 C of the rim 6 B of the box 6 A shown in FIG. 10A . With such arrangement it is possible to provide a selection of a decorative fit frames, for covering the surfaces immediately surrounding the box 6 (not shown) by attaching such frames onto the wall 1 , or surrounding the box 6 A, such as the frame 213 shown in the exploded view of FIG. 10A .
[0046] The frame 213 includes notched surface 213 B and holes 213 C for attaching the frame 213 to the box 6 A or to the wall. The notched surface 213 B fits the rim 213 A of the display device 200 R shown in FIG. 10A and therefore the screws 6 D or other fasteners that are used are fully covered and cannot be seen when the display device is attached as shown in FIG. 10B . By such arrangement it is possible to offer many frame designs with different esthetics and with different methods for attachment to the boxes or the wall such as hooks, studs, clamps or using such materials as bond or bonding tapes and different facilities for matching the frame with the display devices, thereby accommodating the design needs of architects and interior decorators.
[0047] It will of course, be understood by those skilled in the art that the particular embodiment of the invention here presented is by way of illustration only, and is meant to be in no way restrictive, therefore, numerous changes and modifications may be made, and the full used of equivalents resorted to, without departing from the spirit or scope of the inventions as outlined in the appended claims.
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A method for attaching a flat screen display device onto a flat surface using a surface mounted holder is disclosed. The holder includes a plurality of springy electrical contacts and a plurality of hooks each having a latch. The rear surface of the display device includes corresponding electrical contacts for corresponding with the plurality of springy electrical contacts and sockets each with a convex area corresponding to the hooks each having a latch. The method includes mounting the sockets onto the hooks and pushing the display device toward the flat surface by overcoming a biasing force of the springy contacts; and sliding the display device in a direction opposite to the direction of the hooks until the springy electrical contacts engage the corresponding electrical contacts and every convex area is latched by every latch, and is secured by thebiasing force for preventing accidental release of the display device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Divisional of U.S. application Ser. No. 10/105,058 filed on Mar. 21, 2002, which is hereby incorporated by reference for all purposes.
FIELD OF THE INVENTION
The present invention is directed generally to communications over a wireless communications network, and specifically to a message control protocol for a communications network having repeaters.
BACKGROUND OF THE INVENTION
A local on-site wireless monitoring network consists of remote monitoring devices, a central master device for controlling and collecting information from the remote devices, and distributed repeating devices (repeaters). The repeaters provide the means of expanding the communication coverage of the monitoring system by relaying messages to and from the remote devices and the master. Such a monitoring network is useful in many applications, such as, for example, utility meter monitoring, heating ventilation and air conditioning (HVAC) systems, and security systems.
In a simple form, the repeating network includes broadcast type repeaters that receive messages and rebroadcast the message to any other repeating device so that the message can propagate through the network, ultimately arriving at the master device. In such a system, there are no acknowledgment messages between broadcast rounds, as broadcast implies that it is not known who the intended or appropriate receiver should be. Such broadcast systems require little intelligence and are relatively easy to implement and install in practical application. However, such broadcast systems are inherently inefficient in that messages are re-broadcast redundantly in all directions and are received by other repeaters that are further away, as well as closer, to the master. Generally, the master will receive the same message multiple times from multiple paths through the network. This redundancy, although inefficient, is required to ensure a high probability of successful communication of a message from a remote device to the master through the network. In order to avoid endless loops of repeating the same message between two or more repeaters, some method must be employed to limit the number of times that a message is repeated. Limiting the number of times a message is repeated must be balanced with maximizing redundancy to achieve a suitably high probability that the message will ultimately make it to the master. However, limiting the number of times a message is repeated also limits the number of layers of repeaters that can be employed, thus limiting the range of the system.
An alternative to a broadcast network is a directed network where communication between repeaters is more efficient, in that the same message is not repeated unnecessarily, and also more effective at completing communications successfully. A directed network requires a known path from one repeater to the next as a message moves through the network. This known path allows the network to be more efficient and effective in delivering messages from a remote device to the master. Every message passed from one repeater to the next is not repeated by all other repeaters that may have received the message, as happens in a broadcast type system. Every received message is confirmed by an acknowledgment back to the sender so that arbitrary redundancy is not required. Much less communication traffic is generated in a directed network for any given message. Since every passed message is confirmed, a redundant attempt is required only if no acknowledgment occurred. If an attempted communication is not confirmed, an alternate path can be attempted. Thus, the capabilities of a directed network require much more intelligence in the system. For example, every repeater within the system must know where it is within the network, and in relation with other repeaters with which it can communicate in order to propagate a message toward the intended receiver.
In a directed network, layering of repeaters is necessary in order to propagate a message in the intended direction. Each repeater must be assigned an appropriate layer designation. In order to accommodate a relatively large scale system, it may be necessary to repeat an originated message several times, through several layers of repeaters, to get the message to the master. Thus, in such a system, a repeater receives a message, and propagates it to either another repeater which is closer to the master, or to the master itself. Thus, each repeater must be assigned to retransmit messages to another repeater. This assignment of repeaters to layers, and to communicate with specified other repeaters, can become complex.
Referring to FIG. 1 , a diagram illustrating a free space wireless communication network 100 is now discussed. In the communication network 100 , there is a master device 104 , which communicates with a plurality of remote devices 108 . As mentioned above, in order to expand the range of such a communication network 100 , layers of relay devices may be used. In the free space example illustrated in FIG. 1 , three layers of relay devices are illustrated, a first layer having first layer repeaters 112 , a second layer having second layer repeaters 116 , and a third layer having third layer repeaters 120 . The communication network 100 can be used in a number of applications, such as, for example, utility metering where the remote devices 108 transmit usage information to the master device 104 for a particular utility meter. In such a system, the remote devices 108 are connected to a utility meter, such as a electricity or gas meter, and periodically transmit usage information for the utility meter to the master device 104 . Information collected at the master device 104 may then be used for a variety of purposes, such as billing or demand forecasting. The communication network 100 may also be used in other applications, such as in a heating, ventilation, and air conditioning (HVAC) system, where the master device 104 may monitor temperature of other environmental conditions present at the remote devices 108 , and adjust environmental conditions based on the information received from the remote devices 108 . Furthermore, the communication system 100 may be used in applications where the remote devices 108 are mobile, such as a delivery service or a repair/maintenance service where a master device 100 may monitor the status of deliveries being made by a particular courier or the status of a particular repair/maintenance person through periodic check-ins by the courier or repair/maintenance person having a remote device 108 in their possession.
Referring now to FIG. 2 , a practical network 124 is illustrated. As will be understood, the conceptual free space communications network 100 of FIG. 1 is generally not possible to implement. This is due to interference in the signals between a repeater and another repeater or a master or remote. Interference can be the result of, for example, localized radio interference, obstacles, topography or dense foliage in the transmission path. Accordingly, although a repeater may physically be closer to a master than another repeater, the closer repeater may not be able to wirelessly communicate with the master. Hence, the closer repeater will communicate with another repeater, which may be further away, in order to communicate with the master. As illustrated in FIG. 2 , a master 104 communicates with a plurality of remote devices 108 through a number of layers of repeaters. As illustrates, a first level of repeaters 112 can communicate directly with the master 104 . A second level of repeaters 116 communicates with the first level of repeaters 112 , and a third level of repeaters 120 . In the illustration of FIG. 2 , the network has a fourth level of repeaters, 124 , a fifth level of repeaters 128 , a sixth level of repeaters 132 , and a seventh level for repeaters 136 . As can be noted from FIG. 2 , a number of repeaters may be required to connect a remote 108 to the master 104 when obstacles are present. Furthermore, in such a practical network, it is common for new obstacles to enter the network, and for existing obstacles to disappear. Such situations may arise, for example, when building are erected in a communication path, buildings or trees are removed, or a source of radio interference which is introduced or taken away. In such a changing network environment, it becomes increasingly difficult to maintain the directed network configuration, as repeaters have to change the repeater with which they communicate, and often require a change in their layer number. Accordingly, it would be advantageous to have a system in which repeaters may transmit status or maintenance messages for the purpose of keeping a current, and efficient, directed network.
SUMMARY OF THE INVENTION
In accordance with the present invention, a wireless communications network is provided which is able to transmit directed messages to and from devices within the network. In general, the present invention includes a master, a plurality of repeaters, and one or more remote devices. The master, communicates with the remote devices through one or more repeaters in order to transfer information to and from the remote devices. Thus, one aspect of the present invention is to provide a message protocol for communications between devices in the communication network. Further, a method for configuring a wireless communications network is described wherein devices within the network set a communications target based on signal strength of other devices within the network.
In accordance with an embodiment of the present invention, a method for wireless communication between a sending device and a receiving device is provided. The method includes forming a packet at the sending device, wirelessly communicating the packet from the sending device to the receiving device, receiving the packet at the receiving device, and performing a task at the receiving device based on information contained in the packet. The packet includes a plurality of message control bits and a plurality of information fields. At least a first message control bit indicates routing information for the packet, and at least a second message control bit indicates whether data is included in an information field which is associated with the second message control bit. The forming step may include identifying a message type for transmitting to the receiving device, setting the message control bits based on the message type, and formatting data for inclusion in at least one information field based on the message type.
One of the message control bits which may be set (to a binary 1 or alternatively re-set to a binary 0) is a survey bit, which is set when the sending device identifies that the message type is a survey message. In such a case, a survey field, including information related to signal strength, is formatted when the survey bit is set. One of the message control bits which may also be set (alternatively, re-set) is a message control bit, which is set when the message type is a transport message. In such a case, a layer/hop count field, including information related to a layer of the message and a number of times the message has been retransmitted, may be formatted when the layer bit is set. Another message control bit which may be set (or re-set) is an address bit, which is set when the message type is a directed message. In such a case, an address data field is formatted to contain unique identification information of an addressed device to which the message is to be delivered. Another message control bit which may be set (or re-set) is a trace bit, which is set when the message type is a routing trace message. In such a case, a trace data field is formatted to contain information related to the number of addresses contained in the trace data field and unique identification information for each addressed device through which the message has been sent. Another message control bit which may be set (or re-set) is a direction bit, which is set when the message type is an outbound message. First and second remote type bits may also be set as message control bits. In such a case, the first and second remote type bits indicate a type of remote device associated with the message.
The receiving device may retransmit the packet to a second receiving device when the first control bit indicates that the packet is to be retransmitted. The receiving device may also format a response packet including information related to signal strength when one of the message control bits indicates that signal strength information is included in one of the information fields, and transmit the response packet to the sending device. The receiving device may also determine that signal strength information is included in the packet, read the signal strength information, compare the signal strength information with existing signal strength information, and reset a primary contact when the signal strength information indicates that the sending device has a stronger signal strength than an existing primary contact.
In another embodiment of the present invention, a wireless communications system is provided, which includes a master apparatus, at least one remote device, and at least one repeater. The master apparatus includes a memory which is operable to store program and data information, a processor in communication with the memory which is operable to form and receive messages including a first message, with the messages being transmitted and received by a transceiver in communication with the processor. Each of the messages includes a control field and a plurality of information fields, the control field having a plurality of control bits including at least a first control bit indicative of whether data is contained in an information field and at least a second control bit indicative of a direction of transmission for the first message. The remote device(s) include a remote memory operable to store program information and data information, a remote processor in communication with the remote memory which is operable to form and receive messages, the messages transmitted and received by a remote transceiver in communication with the remote processor and operable to transmit and receive the messages. The repeater(s) include a repeater memory operable to store program information and data, a repeater processor in communication with the repeater memory which is operable to form and receive messages, the messages transmitted and received by a repeater transceiver in communication with the repeater processor and operable to transmit and receive messages, wherein the repeater processor is operable to determine if a message is to be re-transmitted based on information contained in the control field.
The control field may include a survey bit that indicates, when in a predetermined state (e.g., a binary 1 or a binary 0), one of the information fields includes information related to signal strength. The control field may also include a layer bit that indicates, when in a predetermined state, one of the information fields includes information related to a layer of the first message and a number of times the first message has been retransmitted. The control field may also include an address bit that indicates, when a predetermined state, one of the information fields includes identification information of a remote device to which the first message is to be delivered. The control field may also include a trace bit that indicates, when in a predetermined state, one of the information fields includes information related to a number of addresses and identification information related to where the first message has been sent or will be sent to. The control field may also include a control bit indicating whether said first message is to be retransmitted.
A first remote device can set a first repeater as its primary contact using signal strength. The first remote device determines that the first repeater is its primary contact based on information received from a plurality of repeaters including the first repeater.
In another embodiment of the present invention, a method for configuring a wireless communications network is provided. In this embodiment, the wireless communications network includes a plurality of remote devices including a first remote device, a plurality of repeaters and a master apparatus. The first remote device determines that the first repeater is a communications target using a message related to signal strength. The determination that the first repeater is a communications target may include transmitting said message related to signal strength from the first remote device and receiving at the first remote device response messages indicative of signal strength from at least some of the plurality of repeaters. The determination may include ascertaining by the first remote device information related to desired signal strength. The desired signal strength relates to a greatest signal strength based on a number of response messages from at least the first repeater. The first remote device may then set the first repeater as the primary contact. The first remote device may repeat, at predetermined time intervals, the determination of a communications target using a message related to signal strength.
Based on the foregoing summary, a number of salient features of the present invention are readily discerned. A wireless communications network which provides directed transmissions between components of the network is provided. The components within the wireless communications make a determination of a communications target, which may be used as a primary contact, automatically, and may repeat the determination at predetermined intervals. Thus, the wireless communications network is able to adapt over time to additional components added into the network, or changing environmental conditions in and around the network.
Additional advantages of the present invention will become readily apparent from the following discussion, particularly when taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating a conceptual free space wireless communication network having repeaters;
FIG. 2 is a diagram illustrating a practical wireless communication network having repeaters;
FIG. 3 is a block diagram illustration of a master, repeater, and remote device of one embodiment of the present invention;
FIG. 4 is a block diagram illustration of a message transport protocol of one embodiment of the present invention;
FIG. 5 is a timing diagram illustration of a portion of a transmission packet of one embodiment of the present invention;
FIG. 6 is a block diagram illustration of a control layer of one embodiment of the present invention;
FIG. 7 is a block diagram illustrating the contents of a control byte of one embodiment of the present invention;
FIG. 8 is a block diagram illustration of a payload layer of one embodiment of the present invention;
FIG. 9 is a block diagram illustration of a message class byte of one embodiment of the present invention;
FIG. 10 is a block diagram illustration of a repeater status byte of one embodiment of the present invention;
FIG. 11 is a block diagram illustration of a payload layer with a configuration byte of one embodiment of the present invention;
FIG. 12 is a flow chart diagram illustrating the operation of a repeater during power up and initialization for one embodiment of the present invention;
FIG. 13 is a flow chart diagram illustrating the operation of a repeater during self-configuration for one embodiment of the present invention;
FIG. 14 is a flow chart diagram illustrating the operation of a message transmission for a repeater for one embodiment of the present invention; and
FIG. 15 is a flow chart diagram illustrating the operation of a periodic neighbor communications check for a repeater for one embodiment of the present invention.
DETAILED DESCRIPTION
Referring now to FIG. 3 , a block diagram illustration of a portion of a wireless communication network 200 of the present invention is described. In its simplest form, the wireless communication network 200 includes a master 204 , a repeater 208 , and a remote device 212 . It will be understood that the wireless communication network 200 may contain a number of repeaters 208 and remote devices 212 . Furthermore, multiple repeaters 208 may be required for the master 204 to communicate with a remote device 212 , in a similar fashion as described above with respect to FIGS. 1 and 2 . In such a case, the repeaters 208 are assigned layer numbers, and transmit messages to repeaters 208 having a lower layer number, for inbound messages to the master 204 , or to repeaters 208 having a higher layer number, for outbound messages away from the master 204 .
The master 204 includes a processor 216 , a memory 220 , and a transceiver 224 . The processor 216 controls communication to and from the master 204 . The memory 220 has a program region 228 for storing program information, and a data region 232 for storing data. The program region 228 may be a non-volatile memory, such as a magnetic media, flash memory, or other memory type. The data region 232 may be volatile memory, such as DRAM or SRAM, and may be periodically backed up to non-volatile memory. The processor 216 operates based on program information in the program region 228 , and retrieves and stores data in the data region 232 . The processor 216 communicates with the transceiver 224 , which is attached to an antenna 236 . The transceiver 224 transmits and receives wireless transmissions through the antenna 236 .
The repeater 208 has a processor 240 , a memory 244 , and a transceiver 248 . The processor 240 controls communication to and from the repeater 208 . The memory 244 has a program region 252 for storing program information, and a data region 256 for storing data. The program region 252 may be a non-volatile memory, such as a magnetic media, flash memory, or other memory type. The data region 256 may be volatile memory, such as DRAM or SRAM, and may be periodically backed up to non-volatile memory. The processor 240 operates based on program information in the program region 252 , and retrieves and stores data in the data region 256 . The processor 240 communicates with the transceiver 248 , which is attached to an antenna 260 . The transceiver 248 transmits and receives wireless transmissions through the antenna 260 .
The remote device 212 has a processor 264 , a memory 268 , and a transceiver 272 . The processor 264 controls communication to and from the remote device 212 . The memory 268 has a program region 276 for storing program information, and a data region 280 for storing data. The program region 276 may be a non-volatile memory, such as a magnetic media, flash memory, or other memory type. The data region 280 may be volatile memory, such as DRAM or SRAM, and may be periodically backed up to non-volatile memory. The processor 264 operates based on program information in the program region 276 , and retrieves and stores data in the data region 280 . The processor 264 communicates with the transceiver 272 , which is attached to an antenna 284 . The transceiver 272 transmits and receives wireless transmissions through the antenna 284 .
The remote device 212 may be one of a number of different types of remote devices, such as a battery powered remote device or a line powered remote device. Furthermore, a remote device 212 may be capable of two-way transmission, both sending and receiving communications through the transceiver 272 and antenna 284 , or may simply be a one-way remote device, periodically sending transmissions. The device may also be a scanning device where the remote device 212 scans through all of the communications channels periodically checking for communications, or a non-scanning device where the remote device 212 simply looks for a transmission on a predetermined channel associated with a predetermined frequency (or frequency range) at a predetermined time. If a remote 212 is a non-scanning device, it is necessary to synchronize the remote with the repeater 208 that it communicates with. Synchronization can also enhance the battery lifetime of a battery powered remote device 212 , as the device is only required to power up and transmit and/or receive at predetermined time intervals.
Communications between the components in the wireless communications network are conducted using a predefined communications protocol. This communications protocol allows different devices, i.e. the master, a repeater, and a remote device, to communicate with each other, and to direct transmission of information to a specified location. FIG. 4 illustrates a block diagram representation of the message transport protocol of one embodiment of the present invention. The message transport protocol uses transmission packets 300 to communicate information between different devices. The transmission packets 300 contain multiple layers of information. A first layer is the transport layer 304 . The transport layer 304 contains all of the information needed to pass information between devices. The transport layer 304 contains a control layer 308 , which has control information used for multiple purposes and which will be described in further detail below. The transport layer 304 also contains a payload layer 312 , which has payload information and which will be described in further detail below.
The transmission packet 300 is simply a tool to transport message data and determine if that data is error free. The content of the message is processed by the processor within each device. The transport layer 304 initially contains a preamble 316 . The purpose of the preamble 316 is to transmit a signature signal to the receiving device that indicates that a message is pending on that particular channel. In one embodiment, the preamble 316 is S ins in length, which corresponds to a scan time of the transceivers in receiving devices. The scan time of the transceivers in the receiving devices is the length of time necessary to scan all of the channels in its channel list. For example, a receiver may scan through 64 channels when looking for an incoming signal. In one embodiment, all of the receivers used in a communication network take a maximum of 5 ins to scan through the 64 channels. Accordingly, by having a 5 ms preamble 316 in this embodiment, the receiver will encounter the preamble 136 at least once in its scan cycle. It will be understood that the length of the preamble 316 may vary depending upon the maximum scan time of the receiving devices, such that the receiver will encounter the preamble 316 at least once in its scan cycle.
In one embodiment, the transmission packet 300 is transmitted using a 100 kBPS transmission rate using the 902-928 MHZ ISM band in the United States under part 15.247 of the Federal Communications Commission (FCC) rules. In this embodiment, the 902-928 MHZ ISM band is split into 64 channels with 400 kHz channel spacing, with data imposed on the carrier with Frequency Modulation (FM) using a peak deviation of 80 kHz. In another embodiment, the transmission packet 300 is transmitted using a 50 kBPS transmission rate using the 868 MHZ band in Europe which is governed by CEPT. In this embodiment, the 868 MHZ band is split into 4 channels with varying channel spacing to avoid restricted portions of the 868 MHZ band, with data imposed on the carrier with FM using a peak deviation of 50 kHz. Digital data is transmitted, in one embodiment, using an asynchronous alternate mark inversion (AMI) line-encoding format on the FM link. In another embodiment, Manchester encoding is used to transmit digital data on the FM link.
In one embodiment, devices within the network employ a listen before talk feature. The listen before talk requires that in any directed messages, the transmitting device checks the transmit channel to be clear of other message carriers before it transmits its message. If the channel is occupied, the transmitter moves to the next channel in sequence and listens again. It continues in this process until a clear channel is found. This process does not apply to broadcast type messages.
The preamble 316 , in the 902-928 MHZ embodiment, consists of a stream of preamble bits transmitted at a rate of 100 kBPS with interspersed 100 microsecond spaces. A timing diagram of this embodiment is illustrated in FIG. 5 . The preamble bits in this embodiment include an initial six binary ones followed by a binary zero. The total of seven bits in the preamble is used in this embodiment because it has a low correlation with noise. However, preambles other than those with such seven bits may be used. The interspersed 100 microsecond spaces allow the receiver to reliably synchronize with the preamble 316 . In the 868 MHZ embodiment, the preamble 316 consists of a stream of preamble bits transmitted at a rate of 50 kBPS with interspersed 200 us spaces. The preamble bits in this embodiment correspond to the byte 0xB8, for similar reasons as described with respect to the 902-928 MHZ embodiment.
Following the preamble 316 in the transport layer 304 is a synchronization (SYNC) frame 320 . The SYNC frame 320 , in one embodiment, contains two bytes. The first byte of the SYNC frame 320 is a network identification (NID) byte 322 . The NID byte 322 is used as a filter mechanism to differentiate communication networks which may have overlapping coverage areas. A NID is assigned to each master 204 at the manufacturing facility, and in one embodiment the NID is determined by hashing a unique serial number of the master 204 . In the event that two adjacent networks have the same NID, the NID of one master can be changed in the field. The discovery of two overlapping networks having the same NID might be made by an operator or installer during installation of one of these two networks. After such installation, such a discovery might be made based on a determination that one or more devices in the overlapping network is not enrolled or recorded as being an authorized device in the particular network. Regardless of the manner of discovery, the operator can initiate the providing of a new NID using the master 200 . In one embodiment, two consecutive zeros following the NID byte 322 signal the end of the preamble 316 .
Following the NID byte 322 in the SYNC frame 320 is a customer identification (CID) byte 324 . The CID byte 324 is used to filter out messages that are not associated with a specific customer. The CID byte 324 may be used to ensure that a specific customer has an exclusive set of unique identification values. The CID byte 324 is assigned to customers on a case-by-case basis. In one embodiment, the CID byte 324 based filtering is disabled in the communications network, and can only be enabled if a CID byte 324 is manually programmed into the network.
Following the SYNC frame 320 in the transport layer 304 is a length (LEN) field 326 . The LEN field 326 is composed of a single byte which follows the SYNC frame 320 . The LEN field 326 indicates the number of bytes to follow in the message. The LEN field 326 includes, in one embodiment, the number of bytes contained in a CRC field. The LEN field 326 , in this embodiment, is one byte, giving a maximum number of bytes following the LEN field 326 of 255 bytes.
Following the LEN field 326 in the transmission packet 300 is the control layer 308 , which will be described in more detail below. Following the control layer 308 is the payload layer 312 , which will also be discussed in more detail below. The final portion of the transmission packet 300 is a CRC field 328 . As will be understood, the CRC field is used to check for errors in the transmitted message. In one embodiment, the CRC field is two (2) bytes long and is based on the well-known CCITT polynomial. The CRC is computed over the entire transmission packet 300 beginning with the SYNC frame 320 .
Referring now to FIGS. 6 and 7 , the control layer 308 will now be described in more detail. The control layer 308 contains a number of fields which are used to route a message through the network. The first field in the control layer 308 is a unique identifier (UID) field and contain a unique identification for the device which originated the massage. The UID field 332 , in one embodiment is four bytes and contains a device identification (DID) portion 336 and a serial number (SN) portion 340 . The DID portion 336 is a one-byte identifier that is unique for a particular type of device. For example, a master 204 , in one embodiment, has a DID portion 336 of zero (0), and repeaters 260 have a DID portion 336 of one (1). The remaining devices are assigned DID portions 336 on a case-by-case basis for a particular market or application. The SN portion 340 follows the DID portion 336 , and is a three-byte identifier which corresponds to a serial number for the device. The DID portion 336 , and the SN portion 340 together faun a unique identification for each device in the network. This information can be used in a number of ways which allow the devices in the network to identify the sending device and associate the sending device with additional information contained in the transmission packet 300 , as will be described in more detail below.
Following the UID field 332 in the control layer 308 is a control (CTL) byte 344 . Each bit within the CTL byte 344 may be independently set and cleared to describe how the transmission packet 300 is to be handled within the network and also indicate if additional control information follows within the control layer 308 . Following the CTL byte 344 is a layer/hop count field 348 which indicates the layer of the message, and the number of times the message is retransmitted as it passes through the network, as will be described in more detail below. Following the layer/hop count field 348 are three optional fields, an optional address data field 352 , an optional survey data field 356 , and an optional trace data field 360 , each of which will be discussed in more detail below.
Referring to FIG. 7 , the individual bits within the CTL byte 344 are now described. In the embodiment of FIG. 7 , the first bit within the CTL byte 344 is a survey (SVY) bit 364 . The SVY bit 364 indicates that signal strength data is included in the optional survey data field 356 . The signal strength data in the optional survey data field 356 includes, in one embodiment, a received signal strength indicator (RSSI) value, a noise floor value, and a serial number of the repeater receiving the message from the origination device. The total length of the optional survey field 356 , in one embodiment, is 5 bytes, and composed of a one-byte RSSI measurement of the repeater, a one-byte noise floor measurement of the channel of the transmission as measured by the repeater, and the repeater's three-byte serial number. This information is passed through the network unmodified and may be used for surveying, locating, and trouble shooting purposes. Survey data is found only on messages that are inbound to a repeater or master and is added by each repeater that receives the message directly from the origination device. Thus, when a repeater receives a message from a remote device, it determines the RSSI and noise floor measurements formats the information into the survey data field 356 and sets the SVY bit 364 in the control byte 344 for the retransmitted message.
In one embodiment, the master uses this survey information to assemble a RSSI matrix. The RSSI matrix is a table maintained by the master that is used for directing outbound messages to specific devices and for network surveying and troubleshooting. The RSSI matrix is formed from periodic supervisory, or status, messages of repeaters and is composed of the RSSI levels measured by the repeaters and master from other repeaters the next layer up in the network. A repeater will transmit a status message as a layered inbound message which will be described in more detail below. Each repeater in the next lower layer which receives this message will append its UID and RSSI level and transmit this message as directed inbound message to the master. The master will retain the UID of all of the repeaters that heard the original message and the RSSI measured from each of those repeaters. Each message received from a remote will be stored in the master with the address of the repeater that heard the original message, the first hop repeater. To send a directed outbound message to a two-way remote, the master will include the UID of the remote and the UID of the first hop repeater. The master will determine from the RSSI matrix what path within the network to take to deliver this message to the repeater (and remote) and attach each repeater's UID to the directed message. The last repeater (first hop repeater) to receive this message will transmit the message directly to the remote.
Using the RSSI matrix, the master will construct a path through the repeater network that the message will travel. The UID of the first hop repeater is always the last address in the path. The RSSI matrix will first be searched for entries in which the source of the status message is the first hop repeater. Of those entries, the UID of the receiving device with the highest measured RSSI is selected. This is the UID of the second hop device and is placed next to last in the path. The RSSI matrix will be searched again for entries in which the source of the status message is the second hop repeater. Of those entries, the UID of the receiving device with the highest measured RSSI is again selected. This UID is placed before the second hop device in the path. The process is continued until the UID in the column is that of the master, which is always the first device in the path of a directed outbound message.
Following the SVY bit 364 in the control byte 344 is a layer (LA) bit 368 . If the LA bit 368 is set, this indicates to the device receiving the message that layer bits in the layer/hop count field 348 are relevant to the repeaters transporting the message. A repeater will only retransmit an outbound message from a layer lower than its own layer, and only retransmit an inbound message from a layer greater than its own. In one embodiment, a repeater is operable to automatically determine its layer, as will be discussed in more detail below. Upon retransmission of an outbound message, a repeater changes the layer number to that of the transmitting repeater. An inbound message with the layer bit 368 set is converted to a directed message by a repeater, having a destination device address. In one embodiment, the layer/hop count field 348 is a one-byte field with the upper three bits representing the number of the layer of the device originating the message. A layer of zero (0) represents the layer of the master. The lower five bits of the layer/hop count field 348 indicate how many times the message has been retransmitted as it is passing through the network.
Following the LA bit 368 in the control byte 344 is an addressed (ADR) bit 372 . The ADR bit 372 is set if the message is being addressed to a particular receiver. In such a case, the control layer 308 includes the optional address data field 352 which contains the UID of the device to which the message is directed. It should be noted that, in this embodiment, the ADR bit 372 and the LA bit 368 are mutually exclusive indicators. A message may not simultaneously be addressed and layered, because an addressed message indicates a specific device which is to receive the message, whereas a layered message merely indicates that a repeater is to retransmit the message either inbound or outbound. In one embodiment, an acknowledgment of an addressed message is required.
Following the ADR bit 372 in the control byte 344 is a trace (TR) bit 376 . The TR bit 376 is set if a routing trace is associated with the transmission packet. A routing trace indicates that trace information is included in the optional trace data field 360 . When the TR bit 376 is set, trace information is added to the optional trace data field 360 for inbound messages, or subtracted from the optional trace data field 360 of outbound messages as the transmission packet 300 moves through the network. Trace information may be used for network troubleshooting or for implementing addressed outbound messages. If an originating remote device requires an inbound message to be traced, it sets the TR bit 376 and sets information in the optional trace data field 360 to zero (0x00). The optional trace data field 360 , in one embodiment, consists of a one-byte count indicating the number of addresses contained in the field, followed by that number of UID's which represent the UID of each hop of the trace, with each UID being 4-bytes in length. If a message is inbound from a remote device to the master, and the message is to be traced, the UID of each successive repeater is post-pended to the trace data field 360 , and the trace count is incremented. If a message which is to be traced is an outbound message from the master to a remote device or repeater, the trace data field 360 is set to include the number of hops and the UID of each device through which the message is to be transferred. At each repeater where the message is retransmitted, the UID of that repeater is removed from the trace data field 360 and the trace count within the trace data field 360 is decremented.
Following the trace bit 376 in the control byte 344 is a direction (DIR) bit 380 . The DIR bit 380 determines the direction that the message is flowing through the network. If the bit is set, it indicates that the message is directed inbound toward the master. If the bit is clear, it indicates that the message is directed outbound away from the master. Following the DIR bit is a utility (UTIL) bit 384 , which may be used to indicate a customized or application specific function within a network.
Following the UTIL, bit 384 in the control byte 344 is a remote type indicator 388 which uses two bits, TY 1 392 , and TY 2 396 . The two bits of the remote type indicator 388 are used to indicate the type of device that originated an inbound message or the type of device that is the destination of an outbound message. In one embodiment, four types of remote devices are present, those being a full two-way device, a one-way remote, a battery powered non-scanning two-way remote, and a line-powered two-way non-scanning remote. Each of these remote devices is assigned a unique value for the remote type, which can be represented in the remote type indicator 388 . It will be understood that certain applications may have fewer types of remote devices present in the network, or may have more types of remote devices in the network. If an application has more than four types of remote devices, the utility bit 384 may be used also, giving up to eight types of remote devices.
Referring now to FIGS. 8 and 9 , the payload layer 312 will now be described. The format and content of the payload layer 312 of the transmission packet 300 is dependent upon the type of message, or message class, being transmitted. The payload layer 312 contains a message class byte (MCB) 400 , and a variable length message field 404 . The length and content of the message field 404 depends upon the message class. FIG. 9 illustrates the content, for one embodiment, of the message class byte 400 . The MCB 400 provides an indication of the content of the message field 404 , thus defining the intended use of the message. The message class byte 400 is divided into a plurality of bit fields, with the lower five (5) bits define a message class field 408 . The five bits of the message class field 408 may thus define thirty-two (32) unique, specific message classes. In one embodiment, two message classes are reserved for network maintenance messages, with the remaining message classes available for application specific messages.
The message class byte 400 also includes a survey bit 412 . When set, the survey bit 412 provides an indication to the first repeater that receives the message to add survey data to the repeated message transmitted from the repeater. The message class byte 400 also includes a payload ID bit 416 . When the payload ID bit 416 is set, it provides an indication that the transmitter application identification is included in the message field 404 . As mentioned above, a transmitter application identification provides an indication of a particular application identification for a remote device. Thus, the master may transmit a message to a remote device having the payload identification bit 416 set, and the remote device will set its application identification to what is contained in the message field 404 . This provides the ability to re-assign an application identification to a transmitter in the field, thus allowing independent control of transmitter identification and compatibility with other systems. For example, a gas metering remote device from a first network may have a different application identification than a gas metering device in a second network. Rather than requiring a specific application identification for such devices, the application identification may be programmed in the field, allowing for more flexibility in the network. The message class byte 400 also includes a sub-class bit 420 . The sub-class bit 420 may be used to indicate that the byte following the message class byte 400 is a sub-class byte. This provides the ability to have additional message class bytes should an application require any such additional bytes.
As mentioned above, in one embodiment, the bits in the message class field 408 may define thirty-two (32) unique, specific message classes, with two message classes are reserved for network maintenance messages. In this embodiment, network maintenance messages are defined by zero (0) and one (1), with the remaining classes (2-31) defining application specific message classes. When a network maintenance message is specified, the bit positions held by the survey bit 412 , payload identification bit 416 , and the sub-class bit 420 are substituted with a number indicating the specific network maintenance message. Thus, up to sixteen (16) network maintenance messages are possible when the network maintenance message classes are selected.
One network maintenance message is a repeater status message. Such a message is transmitted by a repeater to the master, indicating the current status of the repeater. A repeater status message, in one embodiment, includes a one byte message field 404 which contains a repeater status byte 424 , which is illustrated in FIG. 10 . The repeater status byte 424 contains eight status bits, B 0 through B 7 . In one embodiment, a first status bit, B 7 428 indicates the status of a repeaters layer assignment and neighbor list. When set, B 7 428 indicates that the repeater does have a neighbor list and a layer assigned. As will be described in more detail below, a repeater forms a list of repeaters with which it can communicate as a neighbor list, and also has a layer assignment which indicates the relative location of the repeater within the network. A second status bit, B 6 432 , when set indicates that the repeater does not have any primary neighbors. A primary neighbor, as will be described in more detail below, is a repeater which has the strongest signal strength when communicating with the repeater reporting the status message. A third status bit, B 5 436 , when set indicates that the status message is sent as an acknowledgment of a configuration message. Such a status message is transmitted from the repeater in response to receiving a configuration message from the master. A fourth status bit, B 4 440 , when set indicates that the repeater has at least one non-scanning remote synchronized to it. Such non-scanning remote devices do not scan for incoming signals, but rather look for incoming signals at predetermined intervals. A fifth status bit, B 3 444 , when set indicates that the status transmitted by the repeater is supervisory, and that no change has occurred in the repeater configuration since the last status message for the repeater. A sixth status bit, B 2 448 , when set indicates that the case on the repeater has been tampered with. A seventh status bit, B 1 452 , when set indicates that the repeater has a low battery. Finally, an eighth status bit, B 0 456 , does not have a predefined status message associated with it, thus being available for a user defined status, or an application specific status indication.
Another network maintenance message is a repeater configuration message. Such a message may be used to enable or disable specific repeater functions, set timing parameters, signal thresholds, list of IDs to screen, and to force a repeater to initiate an action such as layer reassignment. The payload of the repeater configuration message is formatted with a repeater configuration message class byte, a repeater configure sub-header, and optional data. The repeater configuration message may be transmitted from the master as a broadcast message which is outbound, using a universal serial number so that all of the repeaters in a network can be configured quickly or as a directed message so that individual repeaters may be configured separately. When a message is intended for a specific type of device, such as a repeater the master can use the universal serial number, or universal ID, which in one embodiment is all binary zeros. The master, when using the universal ID, sets the device ID to be the type of device the message is intended for, such as plurality of repeaters or all repeaters in the network. For those repeater configuration messages requiring a response from the repeater, the repeater utilizes a repeater configuration response message class byte, otherwise, a repeater status message is sent as an application acknowledgment with the appropriate bit set in the repeater status byte.
Referring now to FIG. 11 , repeater options within a repeater configure sub-header byte 460 are now described. The repeater configure sub-header byte 460 may have a survey mode bit 464 which indicates, when set, that a survey mode is to be enabled for the repeater. A redundant message screening bit 468 , when set, indicates that the repeater is to screen messages received at the repeater and not retransmit messages which are redundant. A saturation suppression bit 472 , when set, indicates that the repeater is to enable saturation suppression. A trace enable bit 476 , when set, indicates that the repeater is to enable tracing for messages originating from the repeater. A layer reassignment bit 480 , when set, indicates that the repeater is to enable layer reassignment ability, and allow the repeater to reassign its layer number as conditions within the network change. The repeater configure sub-header byte 460 also contains three bits 484 , 488 , 492 which are not set to a predefined indication, thus allowing for application specific or user programmable configurations.
The message field 404 in the repeater configuration message may also contain timing parameters for the repeater. The timing parameters can include repeater check-in time periods, which define the timing of periodic repeater status message transmissions to the master. The timing parameters can also include time between synchronization windows, for use when synchronizing with remote devices. The timing parameters can include a time to remain in synchronization mode following a synchronization request, a time for a saturation suppression entry to be retained, and a time for a redundant message screening entry to be retained.
Furthermore, the message field 404 in the repeater configuration message may also contain signal thresholds to be used by the repeater. The signal thresholds, in one embodiment, are given in values of dBm, and may include a threshold for a valid signal, a sign-on threshold, and a neighbor maintenance threshold, with the sign-on threshold being greater than the neighbor maintenance threshold, which is greater than the valid signal threshold. In one embodiment, the sign-on threshold is about 20 dB above noise, the neighbor maintenance threshold is about 14 dB above noise, and the valid signal for decoding threshold is about 8 dB above noise. Also, the repeater configuration message can also contain a request for the repeater to send noise floor measurements to the master. Upon receiving such a request, the repeater responds with an inbound message that contains a one-byte RSSI measurement for each of the channels used by the repeater, in order, and in units of dBm. The master may then use this information in the RSSI matrix. The message field 404 in the repeater configuration message may also contain an indication that the repeater is to reassign its layer, or enroll a non-scanning two-way remote.
Another network maintenance message is a “ping-me” message. A ping me message is used to solicit a “ping” message. Such a message may be transmitted by a newly installed repeater, or a repeater which has lost touch with the network. Any repeater with a layer assignment, or the master, that receives a ping-me message transmits a “ping” reply message. This allows the originating repeater to build a neighbor list and assign itself a layer number. Two-way remote devices may also generate and transmit a ping-me message to begin the synchronization process. When a repeater receives a ping-me message, it sends a ping message on the same channel that the ping-me was received on. The ping-me message contains a message class byte 400 only, with no additional data contained in the message field 404 .
When responding to a ping-me message, other repeaters, or the master, generate a ping message, which is a separate network maintenance message. Repeaters do not relay ping messages. The ping message transmitted by a repeater, or master, contains the current layer number in the layer/hop count byte 348 . The ping message also contains the RSSI measurement by that repeater, or master, of the ping-me message. In one embodiment, the layer of the master is zero (0). Repeaters that do not have a layer assignment may not respond to a ping-me message. A ping is transmitted in response to a ping-me message and is transmitted on the same channel at the ping-me message using a pseudo-random delay to help prevent interference with responses from other repeaters. In one embodiment, a listen-before-talk is employed before transmitting a ping message, along with an abbreviated preamble, further helping to prevent interference with other repeaters.
Repeaters and scanning two-way remote devices maintain a neighbor list by using a neighbor check network maintenance message, which is transmitted to any neighbors already in the neighbor list of the repeater or remote device. The neighbor check message is transmitted periodically and the response of the neighbor is analyzed to determine if the radio link with that neighbor is still strong enough for that neighbor to be maintained. The responding repeater or master will include the RSSI measurement of the neighbor check message in the response, which is a point-to-point acknowledgment. The neighbor check message is a directed message which is addressed to a specific neighbor that the repeater or remote device is checking. A neighbor may be a primary neighbor or a secondary neighbor. There may be one or more primary neighbors in the neighbor list, and there may be one or more secondary neighbors in the neighbor list. In order for a neighbor to become a primary neighbor, it must be one layer below the repeater building the neighbor list, and its signal threshold must exceed the sign-on threshold. However, to remain a primary neighbor, it must still be only one layer below and its signal strength must exceed the neighbor maintenance threshold so that some signal loss or degradation that may occur over time does not cause it to be removed as a primary neighbor. A secondary neighbor may be one or more layers below the repeater building the neighbor list, and its signal threshold must exceed the neighbor maintenance threshold. If a primary neighbor, after becoming a primary neighbor, has a signal strength less than the neighbor maintenance threshold, it may be removed as a primary neighbor. A secondary neighbor may have an average RSSI which drops below the neighbor maintenance threshold and still be maintained as a secondary neighbor, so long as the average RSSI remains above the valid signal for decoding threshold.
Another network maintenance message which may be generated by a repeater or two-way remote device is a network ID configuration message. This message is used to configure the network ID of the specific repeater or two-way remote. Once the repeater or remote has been enrolled with the master, the master sends the network ID configuration message as a broadcast outbound message using a default network ID (0x00). The UID of the repeater or two-way remote is be configured is located in the trace field 360 , and the new network ID is included in the message field 404 . This message is transmitted several times by the master following the enrollment of the repeater or two-way remote. This message may also be sent by the master when a particular device has failed to transmit a status message during the predetermined supervision window, or at any time when a repeater or two-way remote needs to be re-configured.
A reset message may also be transmitted as a network maintenance message. A device transmits a reset message when it is powered up, or if a manual reset button is pressed. The default NID (0x00) is used to transport the message, and the NID that was recovered from the devices non-volatile memory is included in the payload layer 312 in the message field 404 , along with the reset message class byte 400 . This message is used as part of the registration process and is a broadcast message.
Another network maintenance message is a synchronization request message. A synchronization request message is used by non-scanning two-way remote devices to initiate a synchronization message. A non-scanning remote uses the Ping-me and Ping sequence described above to ascertain a nearby repeater which is most suitable for an entry point to the network. The non-scanning remote then uses the synchronization request message to gather the needed synchronization information from that repeater. The synchronization request is addressed to a particular repeater using the serial number of that repeater. A repeater does not relay a synchronization request message.
When a repeater receives a synchronization request message, it responds to the sending non-scanning remote a synchronization message. The synchronization message is used to transmit a timing configuration of the repeater to the non-scanning remote device. The timing configuration includes a synchronization window period, which is the amount of time between each window when a message is to be transmitted, A synchronization message may also be transmitted by a repeater upon the expiration of a synchronization window, thus acting to re-synchronize the repeater and non-scanning remote in the event that a message is not transmitted during a synchronization window. The synchronization message contains the period, in one embodiment in units of 10 milliseconds, between each window, the time until the next window, and the channel that the next window occurs on. A synchronization message, when transmitted in response to a synchronization request message, is transmitted by the repeater on the same channel that the synchronization request message was received. Once synchronized, the non-scanning remote device does not need to scan for transmissions.
In addition to network maintenance messages, devices in the network may also send message acknowledgment messages. A message acknowledgment is a message used to acknowledge that a message has been properly handed-off from one receiver or remote device to the next repeater or master, or is used as a confirmation of a neighbor check message. The message acknowledgment is a short message sent immediately upon decoding a directed message. It contains a short preamble, the network. ID, the serial number of the acknowledging device, the RSSI measurement of the message being acknowledged, and the CRC of the message as computed by the acknowledging device. If the CRC is incorrect the initiating device retries the transmission. The preamble of the message acknowledgment transmission is, in one embodiment, four binary ones followed by a binary zero. This prevents other devices from locking onto the message acknowledgment transmission. In one embodiment, the device awaiting an acknowledgment allows not less than 3 milliseconds for acknowledgment to begin.
Referring now to FIG. 12 , the operation of a repeater when it is powered on will now be described. Initially, as noted by block 500 , the repeater is powered on. Upon being powered on, the repeater performs an internal system check and diagnostic to verify that internal components are present and communicating with each other properly, as rioted by block 504 . At block 508 , the repeater determines if a network ID (NID) is present in non-volatile memory. If a NID is present, the repeater broadcasts a reset message which includes the NID in the payload layer of the reset message, as noted by block 512 . If the repeater does not have a NID present in non-volatile memory, the repeater broadcasts a reset message which includes a default NID in the payload layer, as noted by block 516 . Following the broadcast of the reset message, the repeater broadcasts a repeater status message, as noted by block 520 . The repeater, at block 524 , waits for and receives a repeater configuration message from the master. Upon receiving the repeater configuration message, the repeater reads the information in the message and sends an acknowledgment message back to the master, as noted by block 528 . The repeater then, according to block 532 , performs a self-configuration routine, which will be described in more detail below.
Referring now to FIG. 13 , the operation of a repeater during self-configuration is now described. Initially, as noted by block 550 , the repeater enters into a self-configuration mode. The repeater broadcasts a ping-me message, as noted by block 554 . The repeater then waits for, and receives ping response messages, as noted by block 558 . As mentioned above, the ping response messages include information on the signal strength of the received ping-me message as well as the layer number and network ID of the responding device. The repeater decodes the ping messages received, and stores the response data in memory, as also is noted by block 558 . The repeater, at block 562 , determines the layer levels and the signal strength of the responses. At block 566 , the repeater sets its layer level based on the ping messages. The layer level is set such that the layer for the repeater is one higher than the lowest layer which the repeater receives a response which has a signal level which was greater than the sign-on threshold. The repeater, at block 570 , sets a primary neighbor list based on the ping responses. As mentioned above, primary neighbors are set to be devices which have signal values which exceed the sign-on threshold and are in the layer immediately lower than the layer of the repeater. The repeater also sets a secondary neighbor list based on the ping responses, as noted by block 574 . The secondary neighbor list, as mentioned above, contains repeaters which may be one or more layers below the repeater. Next, at block 578 , the repeater sends a repeater status message to the master.
Referring now to FIG. 14 , the operation of a device when transmitting a message is now described. Initially, as noted by block 600 , the device transmits a message to a primary neighbor. Following the transmission, the device waits a predetermined time period to determine if it receives an acknowledgment signal, as noted by block 604 . If an acknowledgment signal is received, the device determines if the CRC value of the acknowledgment is correct, as noted by block 608 . If the CRC value is correct, the operation is complete, as noted by block 612 . If the CRC value in the acknowledgment is not correct, or if no acknowledgment is received, the device determines if the transmission has failed three times, as noted by block 616 . In one embodiment, the device tracks the number of transmission attempts using a counter. If the transmission has not failed three times, the operations according to blocks 600 through 616 are performed again. It will be understood that the number of attempts at a transmission can be any preset number of attempts which may be more, or fewer, than three attempts.
If the transmission has failed three times, the device transmits the message to another neighbor, as noted by block 620 . Following the transmission, the device waits a predetermined time period to determine if it receives an acknowledgment signal, as noted by block 624 . If an acknowledgment signal is received, the device determines if the CRC value of the acknowledgment is correct, as noted by block 628 . If the CRC value is correct, the operation is complete, as noted by block 632 . If the CRC value in the acknowledgment is not correct, or if no acknowledgment is received, the device determines if the transmission has failed three times, as noted by block 636 . If the transmission has not failed three times, the device conducts the operations associated with blocks 620 through 636 again. If the transmission has failed three times, the message is converted to a broadcast message that is received or heard by all within its ranges as noted by block 640 . Subsequently, the device, according to block 644 , broadcasts a ping-me message. At block 648 , the device determines whether and ping response messages have been received. If no ping response messages are received, the device waits a predetermined time period, noted in block 652 , and repeats the operations associated with blocks 600 through 640 . If ping response messages are received, as noted by block 656 , the device resets its primary/secondary neighbors based on the ping response messages received. The device, at block 660 , transmits a status message to the master.
Referring now to FIG. 15 , the operation of a repeater when verifying the signal strength of its neighbors is now described. Initially, at noted by block 700 , a repeater broadcasts a periodic signal strength message. In one embodiment, the signal strength message is a ping-me message. At block 704 , the repeater then receives response messages for a predetermined time period. Next, at block 708 , the repeater sorts through the received responses to determine the responses with the lowest layer level which have a signal strength greater than the sign-on threshold level. At block 712 , the repeater sets a primary neighbor list as the repeaters which qualify as primary neighbors. At block 716 , a secondary neighbor list is set to include repeaters which qualify as secondary neighbors. The repeater then operates using the primary/secondary contacts, and at the expiration of a predetermined time period, as noted by block 720 , repeats the operations associated with blocks 700 through 720 .
While an effort has been made to describe some alternatives to the preferred embodiment, other alternatives will readily come to mind to those skilled in the art. Therefore, it should be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not intended to be limited to the details given herein.
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A wireless communications network which provides directed transmissions between components of the network is provided. The components within the wireless communications include a master apparatus, a plurality of remote devices, and a plurality of repeaters. The components within the wireless communications network communicate using messages which have a control field and at least one information field. Information within the control field is used by components to make determinations for retransmitting the message, or transmitting a predefined response to the message, such as a signal strength response. The components within the network use the messages to make a determination of a communications target, which may be used as a primary contact for transmitting information, automatically, and may repeat the determination at predetermined intervals. Thus, the wireless communications network is able to adapt over time to additional components added into the network, or changing environmental conditions in and around the network.
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FIELD OF THE INVENTION
This invention concerns sprinkler systems and installations at the interface between environments having large temperature differences.
BACKGROUND
Sprinkler systems for fire suppression are used to protect structures which separate or enclose adjacent regions having large temperature differences from one another. Examples of such structures include freezers, balconies of apartments, and loading docks of warehouses. Each of these structures has one or more walls and/or ceilings, which separate a region wherein the temperature is maintained above the freezing point of water from a region where the temperature is maintained below freezing or can drop below freezing.
It is a challenge to provide fire protection to such structures, especially when water is the preferred fire suppressing liquid because measures must be taken to ensure that the water does not freeze within the piping network or the sprinklers. To meet this challenge it is known to position the piping network in the temperature controlled “warm” environment where water within the pipes will not freeze, and to provide “dry” type sprinkler assemblies which extend from the piping network through openings in the ceiling or walls of the structure and into the “cold” or uncontrolled environment. An example of such a dry type sprinkler assembly is disclosed in U.S. Pat. No. 5,967,240, hereby incorporated by reference. Such dry sprinkler assemblies have elongated conduits extending between the sprinkler and the piping network with a valve inside to maintain the sprinkler assembly in a “dry” state, i.e., without water, until the sprinkler is activated by the heat from a fire. A heat sensitive trigger, for example a liquid filled frangible bulb, which breaks when subjected to heat from a fire, opens the sprinkler to permit discharge of the water and also acts to open the valve and allow water to flow from the piping network through the conduit and out through the sprinkler.
In prior art sprinkler systems the dry sprinkler assemblies are rigidly connected to the piping network and therefore do not require supplemental support when they extend through the wall or ceiling of the structure into the cold or uncontrolled environment. However, this rigid design is unforgiving with respect to the relative positioning of the openings and the dry sprinkler assemblies, requiring precise alignment between assembly and opening during construction and installation. It would be advantageous to permit flexibility between the dry sprinkler assembly and the piping network so that a greater variation between opening and sprinkler assembly position could be tolerated, thereby simplifying the design and construction of such systems.
SUMMARY OF THE INVENTION
The invention concerns a sprinkler assembly connectable in fluid communication with a piping network carrying a fire suppressing liquid. The sprinkler assembly is extendable through an opening in a substrate. The sprinkler assembly comprises a conduit having a first end connectable to the piping network on one side of the substrate and a second end positionable adjacent to an opposite side of the substrate. A valve associated with the assembly is movable between a closed position to prevent the liquid from entering the conduit, and an open position to allow the liquid to flow through the conduit. In one embodiment the valve is positioned within the conduit. A sprinkler is mounted on the second end of the conduit. A sleeve is positioned within the opening and surrounding the conduit.
In one embodiment, the sleeve is positioned proximate to the first end of the conduit. A portion of the sleeve may extend from the opening. The assembly further comprises an escutcheon positioned on the one side of the substrate and surrounding the opening. The escutcheon may engage the portion of the sleeve extending from the opening.
The assembly may further comprise an escutcheon positioned on the one side of the substrate and surrounding the opening, wherein the escutcheon is mounted on the conduit, for example by screw threads.
Alternately a clamp may engage the conduit and be positioned adjacent to the escutcheon.
A sleeve may also be positioned proximate to the second end of the conduit. A portion of the sleeve may extend from the opening. In this embodiment the assembly may further comprise an escutcheon positioned on the opposite side of the substrate and surrounding the opening, the escutcheon engaging the portion of the sleeve. The escutcheon may mounted on the conduit, for example by screw threads, or a clamp may engage the conduit for attaching the escutcheon to it. Alternately, the escutcheon may be mounted on the sprinkler.
The sleeves may have an inwardly facing surface in contact with an outwardly facing surface of the conduit, and an outwardly facing surface in contact with an inwardly facing surface of the substrate within the opening. Preferably the outwardly facing surface of the sleeves are tapered. The assembly may further comprise a flexible hose attached to the first end of the conduit for connecting the conduit to the piping network.
In another embodiment of a sprinkler assembly connectable in fluid communication with a piping network carrying a fire suppressing liquid, the sprinkler assembly being extendable through an opening in a substrate, the sprinkler assembly comprises a conduit having a first end connectable to the piping network on one side of the substrate and a second end positionable adjacent to an opposite side of the substrate. A valve associated with the assembly is movable between a closed position to prevent the liquid from entering the conduit, and an open position to allow the liquid to flow through the conduit. In one embodiment the valve is positioned within the conduit. A sprinkler is mounted on the second end of the conduit. A first sleeve is positioned within the opening and surrounding the conduit. The first sleeve is positioned proximate to the first end of the conduit. A second sleeve is positioned within the opening and surrounding the conduit. The second sleeve is positioned proximate to the second end of the conduit.
The invention further encompasses a freezer, comprising a compartment defined by a plurality of interconnected substrates. A piping network is positioned outside of the compartment and supplies a fire suppressing liquid. The freezer includes at least one sprinkler assembly comprising a conduit extending through an opening in one of the substrates. The conduit has a first end connected to the piping network on one side of the one substrate and a second end positioned adjacent to an opposite side of the one substrate. A valve associated with the assembly is movable between a closed position to prevent the liquid from entering the conduit, and an open position to allow the liquid to flow through the conduit. In one embodiment the valve is positioned within the conduit. A sprinkler is mounted on the second end of the conduit and a sleeve is positioned within the opening and surrounding the conduit.
In an alternate embodiment the freezer comprises a compartment defined by a plurality of interconnected substrates. A piping network is positioned outside of the compartment and supplies a fire suppressing liquid. The sprinkler includes at least one sprinkler assembly comprising a conduit extending through an opening in one of the substrates. The conduit has a first end connected to the piping network on one side of the one substrate and a second end positioned adjacent to an opposite side of the one substrate. A valve associated with the assembly is movable between a closed position to prevent the liquid from entering the conduit, and an open position to allow the liquid to flow through the conduit. In one embodiment the valve is positioned within the conduit. A sprinkler is mounted on the second end of the conduit. A first sleeve is positioned within the opening and surrounding the conduit, the first sleeve being positioned proximate to the first end of the conduit. A second sleeve is positioned within the opening and surrounding the conduit, the second sleeve being positioned proximate to the second end of the conduit.
The invention also includes a sprinkler installation, comprising a structure comprising a temperature controlled interior space and an exterior space separated from one another by a substrate. A piping network is positioned within the temperature controlled interior space and supplies a fire suppressing liquid. The installation includes at least one sprinkler assembly comprising a conduit extending through an opening in the substrate. The conduit has a first end connected to the piping network and a second end positioned adjacent to the exterior space. A valve associated with the assembly is movable between a closed position to prevent the liquid from entering the conduit, and an open position to allow the liquid to flow through the conduit. In one embodiment the valve is positioned within the conduit. A sprinkler is mounted on the second end of the conduit and extends into the exterior space. A first sleeve is positioned within the opening and surrounding the conduit. The first sleeve is positioned proximate to the first end of the conduit. A second sleeve is positioned within the opening and surrounding the conduit. The second sleeve is positioned proximate to the second end of the conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cut-away isometric view of a freezer sprinkler installation according to the invention;
FIG. 2 is a partial sectional elevational view of a sprinkler installation according to the invention;
FIG. 3 is a sectional view of an example embodiment of a sprinkler assembly according to the invention;
FIGS. 4A and 4B are sectional views of another example embodiment of a sprinkler assembly according to the invention; and
FIGS. 5 through 8 are sectional views of example embodiments of sprinkler assemblies according to the invention.
DETAILED DESCRIPTION
FIG. 1 shows a sprinkler assembly 10 installed in a freezer 12 for fire protection. Freezer 12 comprises a plurality of substrates 14 , in this example forming walls 16 and ceiling 18 interconnected to define a compartment 20 . A piping network 22 is positioned outside of the compartment and supplies a fire suppressing liquid, for example, water, to the sprinkler assembly. The freezer 12 may be located within a building, such as a climate controlled warehouse, wherein the ambient temperature is maintained so that water or other fire suppressing liquid in the piping network 22 does not freeze.
FIG. 2 shows another example sprinkler installation, in this embodiment, a loading dock 26 of a warehouse 28 . The warehouse 28 comprises a temperature controlled interior space 30 defined by a substrate 32 (the exterior wall of the warehouse). The piping network 22 is positioned within the interior space, and the loading dock 26 comprises an exterior space (not temperature controlled) which receives trucks 34 for pick-up and delivery of goods. The local exterior space of the loading dock is protected by the sprinkler assembly 10 according to the invention. It is understood that other similar installations are also feasible, for example a balcony of an apartment, comprising an exterior space where temperature control is not practical, is protected by a sprinkler assembly partially housed in a neighboring interior space (the apartment) which is climate controlled.
FIG. 3 shows in detail an example embodiment of the sprinkler assembly 10 according to the invention. Assembly 10 comprises a conduit 36 having a first end 38 connectable to the piping network 22 on one side 40 of the substrate 14 . Connection to the piping network is advantageously effected by a flexible hose 42 , which could be, for example, a corrugated metal hose or a hose comprising a braided outer sleeve surrounding a flexible inner tubular member. Conduit 36 extends through an opening 44 in the substrate 14 and has a second end 46 positioned adjacent to an opposite side 48 of the substrate 14 . The second end 46 of conduit 36 may extend proud of the substrate as shown, or it may be flush with or beneath the surface of the opposite side 48 . A sprinkler 50 is mounted on the second end 46 of the conduit 36 . The sprinkler has a heat sensitive trigger 52 which operates to open the assembly and allow water or other fire suppressing liquid to flow from the piping network 22 to the sprinkler for discharge onto a fire. Because the second end 46 of conduit 36 is exposed to a cold environment, for example within a freezer compartment, or on the outside of a building, the conduit is normally maintained in a dry state, i.e., without water, to prevent freezing within the conduit. A valve 54 , an example of which is described in detail below, may be positioned within the conduit 36 , and keeps the water within the flexible hose 42 (and within the temperature controlled warm environment) until a fire causes the heat sensitive trigger to open the sprinkler, which also opens the valve 54 and thereby allow water to flow through the conduit 36 to the sprinkler 50 .
It is advantageous to support the sprinkler assembly 10 within the substrate, as it has significant weight which may not be properly supported from the piping network 22 by the flexible hose 42 . To that end a sleeve 56 is positioned within the opening 44 surrounding the conduit 36 . Sleeve 56 may be formed of an insulating material such as natural rubber, EPDM, Buna N, PTFE, silicone, cork or other similar materials. The sleeve 56 has an inwardly facing surface 58 that is in contact with an outwardly facing surface 60 of the conduit 36 . The sleeve also has an outwardly facing surface 62 which contacts an inwardly facing surface 64 within the opening 44 of the substrate 14 . Friction between the various surfaces supports the conduit, and thus the sprinkler assembly 10 in the substrate 14 . Outwardly facing surface 62 of sleeve 56 may be tapered as shown to facilitate insertion of the sleeve into the opening 44 . Sleeve 56 may be longer or shorter than the example shown, as required for effective support of the sprinkler assembly, and may also be positioned anywhere along the length of the conduit 36 within the opening 44 .
FIG. 4A shows another embodiment 66 of a sprinkler assembly according to the invention having a first sleeve 56 a positioned proximate to the first end 38 of the conduit 36 and a second sleeve 56 b positioned proximate to the second end 46 of the conduit. Again, the sleeves may be formed of insulating material such as natural rubber, EPDM, Buna N, PTFE, silicone, cork or other similar materials. As described above, each sleeve 56 a and 56 b may have an inwardly facing surface 58 which contacts the outwardly facing surface 60 of the conduit, and an outwardly facing surface 62 which contacts an inwardly facing surface 64 of the substrate 14 within the opening 44 . Outwardly facing surfaces 62 of sleeves 56 a and 56 b may be tapered, and the sleeves cooperate to support the sprinkler assembly on the substrate.
Additional support for the sprinkler assembly 66 is provided by a pair of escutcheons 68 and 70 positioned surrounding the opening 44 on opposite sides of the substrate 14 . In this example, escutcheon 68 is positioned proximate to the second end 46 of the conduit 36 and is retained to the assembly by engagement with the sprinkler 50 . Note that a portion 72 of second sleeve 56 b extends from the opening 44 and is engaged by the escutcheon 68 . Escutcheon 70 is positioned proximate to the first end 38 of conduit 36 and is mounted on the conduit. In the example shown in FIG. 4A , the escutcheon 70 is retained to the conduit by a clamp 74 , which may be integral with the escutcheon or, as shown, a separate component. Tightening of the clamp 74 cinches it to the conduit and thereby fixes the escutcheons 68 and 70 in contact with respective surfaces 76 and 78 on opposite sides 48 and 40 of the substrate 14 to provide support to the assembly 66 . A portion 80 of first sleeve 56 a extends from opening 44 and is engaged by the escutcheon 70 .
Another sprinkler assembly embodiment 82 is illustrated in FIG. 5 wherein the escutcheon 70 is secured to the conduit 36 threadedly by compatible screw threads 84 and 86 respectively positioned on the escutcheon and the conduit. Rotation of the escutcheon 70 when in contact with the substrate surface 78 draws the escutcheon 68 into contact with the opposite surface 76 and thereby supports the sprinkler assembly 82 on the substrate and between the escutcheons. Note that the escutcheon 68 is shown in phantom line, which indicates that it may be attached to the assembly in one of a number of ways. For example, FIG. 6 shows escutcheon 68 attached to the conduit 36 by a clamp 88 , whereas FIG. 7 shows the escutcheon 68 threadedly attached to the conduit 36 by means of compatible screw threads 90 and 92 respectively on the escutcheon and the conduit 36 . Note that in the example embodiments shown in FIGS. 6 and 7 the second end 46 of the conduit extends from the opening 44 beyond the surface 76 of the substrate. Escutcheon 70 is shown in phantom line in FIGS. 6 and 7 indicating that it could be mounted on the conduit 36 in any one of a number of ways which provide support to the assembly.
FIG. 8 shows a sprinkler assembly embodiment which uses plates 85 , 87 in contact with the substrate surfaces 76 and 78 , respectively, to help distribute loads imposed by the sprinkler assembly onto the substrate 14 . As shown engaging surface 76 , the plate 85 is captured between the surface and an escutcheon 68 mounted on the sprinkler 50 . Plate 87 , engaging opposite surface 78 , is held in place against the surface by a hex nut 89 threaded to the conduit 36 . Nut 89 acts as a compression nut to secure the sprinkler assembly to the substrate upon tightening.
Operation of an example sprinkler assembly applicable to any of the feasible installations is described with reference to FIGS. 4A and 4B . As shown in FIG. 4A , the valve 54 , positioned, in this example, within the conduit 36 , is in its closed configuration which maintains the conduit 36 in a dry condition by keeping water or other fire suppressing fluid in the flexible hose 42 and the piping network 22 . In the closed configuration, a valve closing member 94 is held in sealing engagement with a seat 96 positioned within the conduit 36 proximate to the first end 38 of the conduit 36 by a rod 98 . Rod 98 extends from the valve closing member 94 through the conduit 36 to a cap 100 which covers the opening 102 of sprinkler 50 . Cap 100 is held in position by the heat sensitive trigger 52 , which is supported by the sprinkler arms 104 . Heat sensitive trigger 52 may be, for example, a frangible glass bulb filled with a heat sensitive liquid, or a mechanism held together by a solder having a precisely defined melting temperature. Rod 98 , and therefore the closing member 94 to which it is attached, are biased into the open configuration by a spring element 106 which acts between the seat 96 and a stabilizing spider 108 attached to the rod 98 . As shown in FIG. 4B , when the heat from a fire causes the trigger 52 to break or fall apart it no longer supports the cap 100 , which is subjected to the compression force of spring 106 and water pressure acting on valve closing member 94 through the action of rod 98 . Cap 100 , not being fixedly attached to any part of the sprinkler assembly, falls away and releases the rod 98 . Rod 98 , now unconstrained, moves toward the sprinkler 50 under the biasing force of spring 106 as well as the water pressure against the valve closing member 94 and thus allows the valve closing member to unseat and thereby permit water 110 to flow through the conduit 36 to be discharged from the sprinkler 50 onto the fire.
Sprinkler assemblies according to the invention permit greater flexibility in the design and construction of fire suppression systems by supporting the sprinkler assembly within the substrates forming the structure being protected, and not rigidly from the piping network.
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A sprinkler system installation for fire suppression within a cold environment uses a dry sprinkler assembly connected to a piping network by a flexible hose and supported in a substrate of a structure separating the cold environment from a temperature controlled warm environment. Sleeves of insulating material surround a conduit of the assembly and engage both the conduit and the substrate to seal and provide support. Escutcheons are also provided on opposite sides of the substrate which effect a clamping action on the assembly.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to an integrated circuit (IC) fabrication process. More particularly, the present invention relates to a method for checking the alignment accuracy in a photolithograph process for defining an upper layer with respective to a lower layer on a wafer.
[0003] 2. Description of Related Art
[0004] Generally, besides having to control the critical dimension, alignment accuracy (AA) is also an important factor for determining the success of a photolithograph process of a wafer. Accordingly, the measurement of alignment accuracy, in other words, the measurement of overlay accuracy is an important issue in a semiconductor process. Further, the overlay mark is tool for measuring an overlay error, in which the alignment between a pattern of a photoresist layer and a previously formed layer on the wafer after the lithograph process, is determined.
[0005] Referring to FIG. 1 , when the lower layer 102 in the device region of a wafer is patterned, two trenches 122 a and 122 b in the Y-direction and two trenches 124 a , 124 b in the X-direction are concurrently formed in the non-device region as an outer mark. After the formation of a subsequent upper layer on the wafer, a photolithograph process is performed to concurrently form a photoresist pattern in the device region and two bar-shape photoresist patterns 132 a and 132 b along the Y direction and two bar-shape photoresist patterns 134 a and 134 b along the X direction in the non-device region as an inner mark of an overlay mark.
[0006] Conventionally, the method of using the overlay mark for measuring the alignment accuracy includes measuring the interior profiles and the exterior profiles, respectively, of the Y-directional trenches 122 a and 122 b to obtain the center lines S 122a and S 122b . Further, the center lines S 132a and S 132b of the Y-directional photoresist patterns 132 a and 132 b are obtained. Thereafter, the distance dy 1 between the center lines S 122a and S 132a and the distance dy 2 between the center lines S 122b and S 132b are calculated. If dy 1 is equal to dy 2 , the overlay error in the y direction is 0. The same method is used to determine the overlay error in the X direction. If the overlay errors is both the X direction and the Y direction are not within the acceptable range of deviations, the photoresist layer is removed and the photolithograph process is repeated until the overlay errors are lower than the acceptable range of deviations.
[0007] However, during the fabrication of the trenches 122 a , 122 b , 124 a , 124 b as the overlay marks, the varying positions of the trenches or other factors in the fabrication process may induce unbalance stresses to the lower layer on the wafer. Ultimately, the profiles of two corresponding trenches become asymmetrical, resulting with the X-directional trenches 124 a and 124 b or the Y-directional trenches 122 a and 122 b tilted asymmetrically or their dimensions being different as shown in FIG. 2 . In FIG. 2 , the size of the Y-directional trench 122 b ′ is greater than the size of the Y-directional trench 122 a ′. If the conventional alignment accuracy method is applied for calculating the overlay error, the resulting center lines of the Y-directional trenches 122 a ′/ 122 b ′ are shifted to the positions respectively depicted as S 122 a ′ and S 122 b . Consequently, the differences between the distances dy 1 and dy 2 , which are the distances between the center lines S 122a′ and S 122b′ of the trenches 122 a / 122 b and the center lines S 132a /S 132b of the neighboring photoresist pattern, are not the actual overly error in the Y direction. Ultimately, an overlay shift is resulted. The overlay shift in the X direction and the overlay shift in the Y direction adversely affect the overlay accuracy. More particularly, even dy 1 and dy 2 are equal, the overlay error is not necessary 0. Similarly, even dx 1 and dx 2 are equal, the overlay error in the X-direction is not necessary 0. Hence, the conventional method is unreliable for determining alignment accuracy between the photoresist pattern and the wafer.
SUMMARY OF THE INVENTION
[0008] In view of the foregoing, the present invention provides a method for using an overly mark for checking the alignment accuracy, in which a more preferable inspection result of alignment accuracy is provided.
[0009] The present invention provides a method for checking alignment accuracy, wherein the method is applicable for checking the alignment accuracy in a photolithograph process for defining an upper layer with respect to a lower layer on the wafer. The method includes forming a plurality of overlay marks. The steps of forming the overlay marks of the invention include forming a plurality of outer marks in certain parts of the lower layer during the patterning of the lower layer. Each outer mark further includes an exterior profile and an interior profile. Thereafter, during the photolithograph process, an inner mark is formed within each outer mark above the lower layer. Each inner mark includes an exterior profile and an interior profile. A measurement process is then performed to obtain the relations, for example, the spatial relations, between the interior profiles of the outer marks and the relations between the neighboring inner marks, or the relations between the interior profile of each of the outer marks and each of the neighboring inner marks. Thereafter, these relations are used to calculate the X-directional alignment and the Y-directional alignment between a lower layer on the wafer and an upper pattern layer in a lithography process.
[0010] According to an embodiment the abovementioned method of the invention for checking alignment accuracy, the distance between the interior profile of each neighboring outer mark and the center line of each neighboring inner mark.
[0011] According to an embodiment of the above-mentioned method for checking the alignment accuracy of the invention, the outer marks are formed by forming 2 X-directional trenches and two Y-directional trenches in the lower layer on the wafer.
[0012] According to an embodiment of the above-mentioned method of the invention for checking the alignment accuracy, the method of forming the inner marks includes patterning a photoresist layer used in the photolithography process to form two X-directional bars and two Y-directional bars.
[0013] According to an embodiment of the above-mentioned method of the invention for checking alignment accuracy, the distances dx 1 and dx 2 between the center lines of the interior profiles of the two X-directional trenches and the two corresponding X-directional bars, and the distances dy 1 and dy 2 between the center lines of the interior profiles of the two Y-directional trenches and the two corresponding Y-directional bars are obtained during the measurement process.
[0014] According to an embodiment of the above-mentioned method of the invention for checking alignment accuracy, when dx 1 =dx 2 and dy 1 =dy 2 , the lower layer on the wafer is completely aligned with the upper pattern layer for the photolithograph process.
[0015] According to an embodiment of the above-mentioned method of the invention for checking alignment accuracy, the distance between the interior profile of each outer mark and the interior profile of each neighboring inner mark is obtained in the measurement process. Further the distance is used to calculate the X-directional alignment and the Y-directional alignment in a photolithography process with respect to the lower layer on the wafer.
[0016] According to an embodiment of the above-mentioned method of the invention for checking alignment accuracy, the distance between the interior profile of each outer mark and the exterior profile of each neighboring outer mark is obtained in the measurement process. Further the distance is used to calculate the X-directional alignment and the Y-directional alignment in a photolithography process with respect to the lower layer on the wafer.
[0017] According to an embodiment of the above-mentioned method of the invention for checking alignment accuracy, the relation between center line between the interior profiles of the outer marks and the center line between the center lines of the neighboring inner marks is obtained in the measurement process.
[0018] According to an embodiment of the above-mentioned method of the invention for checking alignment accuracy, the relation between center line between the interior profiles of the outer marks and the center line between the exterior profiles of the neighboring inner marks is obtained from the measurement process.
[0019] According to an embodiment of the above-mentioned method of the invention for checking alignment accuracy, the relation between the center line between the interior profiles of the outer marks and the center line between the interior profiles of the neighboring inner marks is obtained in the measurement process.
[0020] Using the above method for checking the alignment of the overlay marks, the profiles and the dimensions of the alignment marks being asymmetrical can be obviated. More particularly, the error in overlay measurement accuracy resulting from a profile deformity of the exterior profile of the outer mark is mitigated. Ultimately, the results from checking alignment accuracy are desirable.
[0021] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0023] FIG. 1 is a schematic diagram illustrating one type of overlay mark and an application thereof according to the prior art.
[0024] FIG. 2 is schematic diagram illustrating another type of overlay mark and an application thereof according to the prior art.
[0025] FIG. 3 is a schematic diagram illustrating one type of overlay mark according to an embodiment of the invention.
[0026] FIG. 4 is a schematic diagram illustrating one type of overlay mark and an application thereof according to an embodiment of the invention.
[0027] FIG. 5 is a schematic diagram illustrating one type of overlay mark and an application thereof according to an embodiment of the invention.
[0028] FIG. 6 is a schematic diagram illustrating one type of overlay mark and an application thereof according to an embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] FIGS. 3 , 4 , and 5 are schematic diagrams respectively illustrating the overlay mark of the present invention and an application thereof. In this exemplary embodiment, the overlay mark includes, for example, two X-directional, orthogonal trenches and two Y-directional, orthogonal trenches as the outer mark, and two X-directional bars and two Y-directional bars as the inner mark. However, it is appreciated that the shapes and the configurations of the overlay mark introduced herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
[0030] Referring to FIG. 3 , as the lower layer 302 in the device region of a wafer 300 is being patterned, an outer mark 320 is concurrently formed in the non-device region. The outer mark 320 may constitute with, but not limited to, two Y-directional trenches 322 a , 322 b and two X-directional trenches 324 a , 324 b . Each trench also includes an exterior profile T o and an interior profile T i . The lower layer 302 is a dielectric layer, for example. The non-device region is a scribe line region, for example. During the etching of the trenches 322 a , 322 b , 324 a and 324 b , the various positions of these trenches or other factors in the fabrication process may induce unbalance stresses to the lower layer on the wafer, causing the profiles of two corresponding trenches asymmetrically formed. Ultimately, the X-directional trenches 324 a , 324 b or the Y-directional trenches 322 a , 322 b may tilt asymmetrically or their sizes are different. As shown in FIG. 3 , the size of the Y-directional trench 322 b is greater than that of the Y-directional trench 322 a.
[0031] Thereafter, an upper layer (not shown) is formed over the wafer 300 . The upper wafer layer includes but not limited to a metal layer. After forming the upper layer (not shown), a photoresist pattern of the device region and the inner mark 330 of the overlay mark are concurrently formed in a photolithograph process. The inner mark 330 is configured within the outer mark 320 . The inner mark 330 includes but not limited to two Y-directional bar-shape photoresist patterns 332 a , 322 b and two X-directional bar-shape photoresist patterns 334 a , 334 b.
[0032] Still referring to FIG. 3 , the method for measuring alignment accuracy using the overlay mark according to an embodiment of the invention includes using the interior profile T i1 of the outer mark 320 as the bench mark for calculating alignment accuracy, and not using the relation between the interior profile T i1 and the exterior profile T o1 of the outer mark 320 as a bench mark for calculating alignment accuracy. In one embodiment, the method of the invention includes measuring the relation, for example, the spatial relation between the interior profile T i1 of each outer mark 320 and the neighboring inner mark 330 . For example, the distance between the interior profile T i1 of the outer mark 320 and the center line S of the neighboring inner mark 330 is measured or the distance between the interior profile T i1 of the outer mark 320 and the interior profile T i2 of the neighboring inner mark 330 or the distance between the interior profile T i1 of the outer mark 320 and the exterior profile T o2 of the neighboring inner mark 330 , etc.
[0033] In another embodiment, the relations between these interior profiles T i1 of the outer marks 320 are measured and the relations between the neighboring inner marks 330 are measured. For example, the spatial relation between the center line between two interior profiles T i1 of the corresponding outer marks 320 and the center line S between the center lines of the two corresponding neighboring inner marks 330 is measured; or the spatial relation between the center line between two corresponding interior profiles T i1 of the outer marks 320 and center line between the interior profiles T i2 of two corresponding neighboring inner marks 330 is measured; or the spatial relation between the center line between the interior profiles T i of the corresponding outer marks 320 and the center line between the exterior profiles T o2 of the two corresponding neighboring inner marks 330 .
[0034] Thereafter, these measurements of spatial relations are used to calculate the alignment for a photolithograph process with respect to the lower wafer level.
[0035] Continuing to FIG. 4 , in an embodiment of which a bar-in-bar typeof mark is used, the distance d between the interior profile Ti of each outer mark 320 and the center line of each neighboring inner mark 330 is measured. In this embodiment, the distance d y1 between the interior profile T i1 of the Y-directional trench 322 a and the center line S 332a of the corresponding Y-directional bar 322 a is measured; the distance d y2 between the interior profile T i1 of the Y-directional trench 322 b and the center line S 332 b of the corresponding Y-directional bar 322 b is measured; the distance d x1 between the interior profile T i1 of the X-directional trench 324 a and the center line S 334a of the corresponding X-directional bar 334 a is measured; and the distance d x2 between the interior profile T i1 of the X-directional trench 324 b and the center line S 334b of the corresponding X-directional bar 334 b is measured.
[0036] Thereafter, the distances dy 1 , dy 2 and dx 1 and dx 2 are used to calculate the X-directional alignment and the Y-directional alignment for a photolithograph process with respect to the lower layer on the wafer. If dy 1 =dy 2 , the overlay error in the Y direction is 0. If dx 1 =dx 2 , the overlay error in the X direction is 0. If dx 1 =dx 2 and dy 1 =dy 2 for all the overlay marks, the lower layer is completely aligned with an upper pattern layer, for example, a photoresist pattern, for the photolithograph process.
[0037] When the lower layer on the wafer is completely aligned with the photoresist pattern for the photolithograph process, or the X-directional overlay error and the Y-directional overlay error are within a prescribed range of deviations, the next process step may proceed. If the overlay errors in the X-direction and in the Y-direction are greater than the acceptable range of deviations, the required alignment between the photoresist pattern and the wafer has not achieved. Hence, the photoresist layer is removed and the photolithography process is repeated until the overlay error is within the acceptable range of deviations.
[0038] In the above embodiment, the measuring of the distance between the interior profile T i1 of an outer mark 320 and the center line S of the neighboring inner mark 330 is used to illustrate the technique of the invention. In an actual application, the distance between the interior profile T i1 of the outer mark 320 and the interior profile T i2 of the neighboring inner mark 330 , or the distance between the interior profile T i1 of the inner mark 320 and the exterior profile T o2 of the neighboring inner mark 320 can be measured for calculating alignment.
[0039] Referring to FIG. 5 , in another embodiment, the center line between two interior profiles T i1 of the corresponding outer marks 320 and the center line between the neighboring inner marks 330 are respectively measured. The overlay error is calculated based on the positions of the two center lines. In this embodiment, the center line S 322 between the interior profile of the Y-directional trench 322 a and the interior profiles T i1 of the Y-directional trench 322 b is measured; the center line S 332 between the center line S 332a of the Y-directional bar 332 a and the center line S 332b of the Y-directional bar 332 is measured; the center line S 334 between the interior profile Ti of the X-directional trench 324 a and the interior profile T i1 of the X-directional trench 324 b is measured; and the center line S 334 between the center line S 334a of the X-directional bar 334 a and the center line S 334b of the X-directional bar 334 b is measured.
[0040] Thereafter, the distance Dy between the Y-directional center lines S 324 and S 334 and the distance Dx between the X-directional center lines S 324 and S 334 are measured for calculating the X-directional alignment and the Y-directional alignment in the photolithography process with respect to the lower layer on the wafer. If Dy is 0, the overlay error in the Y-direction is 0. If Dx is 0, the overlay error in the X-direction is 0. If the Dx and Dy of each overly mark on the wafer is 0, the lower layer on the wafer is completely aligned with the upper pattern layer in the photolithograph process.
[0041] When the lower layer on the wafer is completely aligned with the upper pattern layer in the photolithograph process or the overlay errors in the X-direction and in the Y-direction are within the prescribed range of deviations, a next process step may proceed. If the overlay errors in the X-direction and in the Y-direction are greater than the prescribed range of deviations, the alignment between the photoresist pattern and the wafer has not achieved. In such a case, the photoresist layer must be removed and the photolithography process must be repeated until the overlay errors are within the acceptable range of deviations.
[0042] In the above embodiment, the spatial relation between the center line of two corresponding interior profiles T i2 of the outer marks and the center line S of the center lines of two corresponding neighboring inner marks is measured for illustrating the technique of the invention. However, in an actual application, the relation between the center line between two corresponding interior profiles T i of the outer marks 320 and the center line T i2 between the interior profiles of two corresponding neighboring inner marks 330 , or the relation between the center line between the interior profiles T i of corresponding inner marks 320 and the center line between the exterior profiles T o2 of two corresponding neighboring inner marks 330 may be measured for calculating alignment.
[0043] In the above two embodiments, the interior profile of the outer mark is used as a basis for calculating alignment by using different mathematical calculation methods. However, it should be appreciated that the application of the technique introduced here is not restricted to mathematical calculation methods and this invention shall not be construed as limited to the embodiments set forth herein.
[0044] The invention applies the interior profiles of the various outer marks of the overlay mark for calculating alignment. Not only the profile distortion of the overlay mark generated due to changes of the profile or the dimension of the mark during the fabrication process can be mitigated, the accuracy of overlay measurement can be enhanced.
[0045] Further, in the above embodiment, the bar-in-bar type of mark is used to illustrate the present invention. It is to be understood and appreciated that the method described herein may be practiced in conjunction of a bar-in-frame type of overlay mark. Referring to FIG. 6 , the overlay mark includes a frame-shape trench as the outer mark 420 , and two X-directional bars 434 a and 434 b and two Y-directional bars 432 a and 432 b as the inner mark 430 . During the patterning of the lower wafer layer 402 in the device region of a wafer 400 , an outer mark 420 is concurrently formed in the non-device region. The outer mark 420 is, for example, a frame-shape trench constitute with two Y-directional trenches 422 a and 422 b and two X-directional trenches 424 a and 424 b . The frame shaped trench includes one exterior profile T o and an interior profile T i . The lower layer 402 is a dielectric layer, for example. The non-device region is a scribe line region, for example. During the etching of the trenches 422 a , 422 b , 424 a and 424 b , the various positions of these trenches or other factors in the fabrication process may induce unbalance stresses to the lower layer on the wafer, causing the profiles of two corresponding trenches asymmetrically formed. Ultimately, the X-directional trenches 424 a , 424 b or the Y-directional trenches 422 a , 422 b may tilt asymmetrically or their sizes are different. As shown in FIG. 6 , the size of the Y-directional trench 422 b is greater than that of the Y-directional trench 422 a , for example.
[0046] Thereafter, an upper layer (not shown) is formed over the wafer 400 . The upper layer includes but not limited to a metal layer. After forming the upper layer (not shown), a photoresist pattern of the device region and the inner mark 430 of the overlay mark are concurrently formed in a photolithograph process. The inner mark 430 is configured within the outer mark 420 . The inner mark 430 includes but not limited to two Y-directional bar-shape photoresist patterns 432 a , 422 b and two X-directional bar-shape photoresist patterns 434 a , 434 b.
[0047] According to the method for measuring alignment accuracy using the overlay mark of this embodiment of the invention includes using the interior profile T i1 of the outer mark 420 as the bench mark for calculating alignment accuracy, instead of using the relation between the interior profile T i1 and the exterior profile T o1 of the outer mark 420 as a bench mark for calculating alignment accuracy. The method of calculating the alignment accuracy is similar to the method described above; a detail description thereof is omitted herein.
[0048] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing descriptions, it is intended that the present invention covers modifications and variations of this invention if they fall within the scope of the following claims and their equivalents.
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A method for checking the alignment accuracy using an overlay mark is provided. The overlay mark includes an inner mark and an outer mark formed on a wafer. The outer mark is formed in a lower layer on the wafer when the lower layer is patterned. The inner mark is formed within the outer mark over the lower layer when a lithography process for defining an upper layer is performed. A measurement process is conducted to obtain a first relation between each of the interior profiles of the outer marks and a second relation between each of the inner marks. Alternatively, a third relation between each of the interior profiles of the outer marks and each of the inner marks is obtained. The X-directional alignment accuracy and y-directional alignment accuracy are computed according to the first and the second relations, or the third relation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/246,959 filed on Oct. 7, 2008. This application claims the benefit of U.S. Provisional Application No. 60/978,258, filed on Oct. 8, 2007. The entire disclosures of each of the above applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to compressors, and more particularly, to a protection system for use with a variable speed compressor.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] Compressors may be used in a wide variety of industrial and residential applications to circulate refrigerant within a refrigeration, heat pump, HVAC, or chiller system (generically “refrigeration systems”) to provide a desired heating or cooling effect. In any of the foregoing applications, the compressor should provide consistent and efficient operation to insure that the particular application (i.e., refrigeration, heat pump, HVAC, or chiller system) functions properly. A variable speed compressor may be used to vary compressor capacity according to refrigeration system load.
[0005] Operation of the compressor during a flood back condition is undesirable. A flood back condition occurs when excessive liquid refrigerant flows into the compressor. Severe flood back can dilute the oil and reduce its lubrication property, leading to potential seizure. Although some mixture of liquid refrigerant and oil in the compressor may be expected, excessive mixture may cause damage to the compressor.
[0006] Likewise, operation of the compressor at excessive temperature levels may be damaging to the compressor. An overheat condition may damage internal compressor components including, for example, the electric motor.
SUMMARY
[0007] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
[0008] A system is provided that includes a compressor connected to a condenser and a discharge line temperature sensor that outputs a discharge line temperature signal corresponding to a discharge line temperature of refrigerant leaving the compressor. The system also includes a control module connected to the discharge line temperature sensor. The control module determines a saturated condenser temperature, calculates a discharge superheat temperature based on the saturated condenser temperature and the discharge line temperature, and monitors a flood back condition of the compressor by comparing the discharge superheat temperature with a predetermined threshold. The control module also increases a speed of the compressor or decreases an opening of an expansion valve associated with the compressor when the discharge superheat temperature is less than or equal to the predetermined threshold.
[0009] A method is also provided and includes determining, with a control module, a saturated condenser temperature of a condenser connected to a compressor. The method also includes receiving, with the control module, a discharge line temperature signal that corresponds to a discharge line temperature of refrigerant leaving the compressor. The method also includes calculating, with the control module, a discharge superheat temperature based on the saturated condenser temperature and the discharge line temperature. The method also includes monitoring, with the control module, a flood back condition of the compressor by comparing the discharge superheat temperature with a predetermined threshold. The method also includes increasing a speed of the compressor or decreasing an opening of an expansion valve associated with the compressor when the discharge superheat temperature is less than or equal to the predetermined threshold.
[0010] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0011] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0012] FIG. 1 is a schematic illustration of a refrigeration system.
[0013] FIG. 2 is a perspective view of a compressor with an inverter drive.
[0014] FIG. 3 is another perspective view of a compressor with an inverter driver.
[0015] FIG. 4 is a cross-section view of a compressor.
[0016] FIG. 5 is a graph showing discharge super heat correlated with suction super heat and outdoor temperature.
[0017] FIG. 6 is a graph showing condenser temperature correlated with compressor power and compressor speed.
[0018] FIG. 7 is a graph showing an operating envelope of a compressor.
[0019] FIG. 8 is a graph showing condensing temperature correlated with evaporator temperature and compressor power for a given compressor speed.
[0020] FIG. 9 is a graph showing discharge line temperature correlated with evaporator temperature and condenser temperature.
[0021] FIG. 10 is a flow chart showing derived data for a refrigeration system.
[0022] FIG. 11 is a schematic of a refrigeration system.
[0023] FIG. 12 is a flow chart showing derived data for a refrigeration system.
[0024] FIG. 13 is a graph showing mass flow correlated with inverter drive heat loss.
[0025] FIG. 14 is a graph showing inverter speed correlated with inverter efficiency.
[0026] FIG. 15 is a graph showing a control module with measured inputs and derived outputs.
[0027] FIG. 16 is a schematic of a refrigeration system.
[0028] FIG. 17 is a cross-section view of a compressor.
DETAILED DESCRIPTION
[0029] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0030] As used herein, the terms module, control module, and controller may refer to one or more of the following: An application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality. As used herein, computer readable medium may refer to any medium capable of storing data for a computer or module, including a processor. Computer-readable medium includes, but is not limited to, memory, RAM, ROM, PROM, EPROM, EEPROM, flash memory, CD-ROM, floppy disk, magnetic tape, other magnetic medium, optical medium, or any other device or medium capable of storing data for a computer.
[0031] With reference to FIG. 1 , an exemplary refrigeration system 5 includes a compressor 10 that compresses refrigerant vapor. While a specific refrigeration system is shown in FIG. 1 , the present teachings are applicable to any refrigeration system, including heat pump, HVAC, and chiller systems. Refrigerant vapor from compressor 10 is delivered to a condenser 12 where the refrigerant vapor is liquefied at high pressure, thereby rejecting heat to the outside air. The liquid refrigerant exiting condenser 12 is delivered to an evaporator 16 through an expansion valve 14 . Expansion valve 14 may be a mechanical or electronic valve for controlling super heat of the refrigerant. The refrigerant passes through expansion valve 14 where a pressure drop causes the high pressure liquid refrigerant to achieve a lower pressure combination of liquid and vapor. As hot air moves across evaporator 16 , the low pressure liquid turns into gas, thereby removing heat from evaporator 16 . The low pressure gas is again delivered to compressor 10 where it is compressed to a high pressure gas, and delivered to condenser 12 to start the refrigeration cycle again.
[0032] With reference to FIGS. 1 , 2 and 3 , compressor 10 may be driven by an inverter drive 22 , also referred to as a variable frequency drive (VFD), housed in an enclosure 20 . Enclosure 20 may be near compressor 10 . Inverter drive 22 receives electrical power from a power supply 18 and delivers electrical power to compressor 10 . Inverter drive 22 includes a control module 25 with a processor and software operable to modulate and control the frequency of electrical power delivered to an electric motor of compressor 10 . Control module 25 includes a computer readable medium for storing data including the software executed by the processor to modulate and control the frequency of electrical power delivered to the electric motor of compressor and the software necessary for control module 25 to execute and perform the protection and control algorithms of the present teachings. By modulating the frequency of electrical power delivered to the electric motor of compressor 10 , control module 25 may thereby modulate and control the speed, and consequently the capacity, of compressor 10 .
[0033] Inverter drive 22 includes solid state electronics to modulate the frequency of electrical power. Generally, inverter drive 22 converts the inputted electrical power from AC to DC, and then converts the electrical power from DC back to AC at a desired frequency. For example, inverter drive 22 may directly rectify electrical power with a full-wave rectifier bridge. Inverter driver 22 may then chop the electrical power using insulated gate bipolar transistors (IGBT's) or thyristors to achieve the desired frequency. Other suitable electronic components may be used to modulate the frequency of electrical power from power supply 18 .
[0034] Electric motor speed of compressor 10 is controlled by the frequency of electrical power received from inverter driver 22 . For example, when compressor 10 is driven at sixty hertz electric power, compressor 10 may operate at full capacity operation. When compressor 10 is driven at thirty hertz electric power, compressor 10 may operate at half capacity operation.
[0035] Piping from evaporator 16 to compressor 10 may be routed through enclosure 20 to cool the electronic components of inverter drive 22 within enclosure 20 . Enclosure 20 may include a cold plate 15 . Suction gas refrigerant may cool the cold plate prior to entering compressor 10 and thereby cool the electrical components of inverter drive 22 . In this way, cold plate 15 may function as a heat exchanger between suction gas and inverter drive 22 such that heat from inverter drive 22 is transferred to suction gas prior to the suction gas entering compressor 10 .
[0036] As shown in FIGS. 2 and 3 , electric power from inverter drive 22 housed within enclosure 20 may be delivered to compressor 10 via a terminal box 24 attached to compressor 10 .
[0037] A compressor floodback or overheat condition is undesirable and may cause damage to compressor 10 or other refrigeration system components. Suction super heat (SSH) and/or discharge super heat (DSH) may be correlated to a flood back or overheating condition of compressor 10 and may be monitored to detect and/or predict a flood back or overheating condition of compressor 10 . DSH is the difference between the temperature of refrigerant vapor leaving the compressor, referred to as discharge line temperature (DLT) and the saturated condenser temperature (Tcond). Suction super heat (SSH) is the difference between the temperature of refrigerant vapor entering the compressor, referred to as suction line temperature (SLT) and saturated evaporator temperature (Tevap).
[0038] SSH and DSH may be correlated as shown in FIG. 5 . The correlation between DSH and SSH may be particularly accurate for scroll type compressors, with outside ambient temperature being only a secondary effect. As shown in FIG. 5 , correlations between DSH and SSH are shown for outdoor temperatures (ODT) of one-hundred fifteen degrees Fahrenheit, ninety-five degrees Fahrenheit, seventy-five degrees Fahrenheit, and fifty-five degrees Fahrenheit. The correlation shown in FIG. 5 is an example only and specific correlations for specific compressors may vary by compressor type, model, capacity, etc.
[0039] A flood back condition may occur when SSH is approaching zero degrees or when DSH is approaching twenty to forty degrees Fahrenheit. For this reason, DSH may be used to detect the onset of a flood back condition and its severity. When SSH is at zero degrees, SSH may not indicate the severity of the flood back condition. As the floodback condition becomes more severe, SSH remains at around zero degrees. When SSH is at zero degrees, however, DSH may be between twenty and forty degrees Fahrenheit and may more accurately indicate the severity of a flood back condition. When DSH is in the range of thirty degrees Fahrenheit to eighty degrees Fahrenheit, compressor 10 may operate within a normal range. When DSH is below thirty degrees Fahrenheit, the onset of a flood back condition may occur. When DSH is below ten degrees Fahrenheit, a severe flood back condition may occur.
[0040] With respect to overheating, when DSH is greater than eighty degrees Fahrenheit, the onset of an overheating condition may occur. When DSH is greater than one-hundred degrees Fahrenheit, a severe overheating condition may be present.
[0041] In FIG. 5 , typical SSH temperatures for exemplar refrigerant charge levels are shown. For example, as the percentage of refrigerant charge in refrigeration system 5 decreases, SSH typically increases.
[0042] To determine DSH, DLT may be subtracted from Tcond. DLT may be sensed by a DLT sensor 28 that senses a temperature of refrigerant exiting compressor 10 . As shown in FIG. 1 , DLT sensor 28 may be external to compressor 10 and may be mounted proximate a discharge outlet of compressor 10 . Alternatively, an internal DLT sensor 30 may be used as shown in FIG. 4 . In FIG. 4 , a cross-section of compressor 10 is shown. Internal DLT sensor 30 may be embedded in an upper fixed scroll of a scroll compressor and may sense a temperature of discharge refrigerant exiting the intermeshing scrolls.
[0043] In the alternative, a combination temperature/pressure sensor may be used. In such case, Tcond may be measured based on the pressure of refrigerant exiting compressor 10 as measured by the combination sensor. Moreover, in such case, DSH may be calculated based on DLT, as measured by the temperature portion of the sensor, and on Tcond, as measured by the pressure portion of the combination sensor.
[0044] Tcond may be derived from other system parameters. Specifically, Tcond may be derived from compressor current and voltage (i.e., compressor power), compressor speed, and compressor map data associated with compressor 10 . A method for deriving Tcond based on current, voltage and compressor map data for a fixed speed compressor is described in the commonly assigned application for Compressor Diagnostic and Protection System, U.S. application Ser. No. 11/059,646, Publication No. U.S. 2005/0235660. Compressor map data for a fixed speed compressor correlating compressor current and voltage to Tcond may be compressor specific and based on test data for a specific compressor type, model and capacity.
[0045] In the case of a variable speed compressor, Tcond may also be a function of compressor speed, in addition to compressor power.
[0046] A graphical correlation between compressor power in watts and compressor speed is shown in FIG. 6 . As shown, Tcond is a function of compressor power and compressor speed. In this way, a three-dimensional compressor map with data correlating compressor power, compressor speed, and Tcond may be derived for a specific compressor based on test data. Compressor current may be used instead of compressor power. Compressor power, however, may be preferred over compressor current to reduce the impact of any line voltage variation. The compressor map may be stored in a computer readable medium accessible to control module 25 .
[0047] In this way, control module 25 may calculate Tcond based on compressor power data and compressor speed data. Control module 25 may calculate, monitor, or detect compressor power data during the calculations performed to convert electrical power from power supply 18 to electrical power at a desired frequency. In this way, compressor power and current data may be readily available to control module 25 . In addition, control module 25 may calculate, monitor, or detect compressor speed based on the frequency of electrical power delivered to the electric motor of compressor 10 . In this way, compressor speed data may also be readily available to control module 25 . Based on compressor power and compressor speed, control module 25 may derive Tcond.
[0048] After measuring or calculating Tcond, control module 25 may calculate DSH as the difference between Tcond and DLT, with DLT data being receiving from external DLT sensor 28 or internal DLT sensor 30 .
[0049] Control module 25 may monitor DSH to detect a flood back or overheat condition, based on the correlation between DSH and flood back and overheat conditions described above. Upon detection of a flood back or overheat condition, control module 25 may adjust compressor speed or adjust expansion valve 14 accordingly. Control module 25 may communicate with or control expansion valve 14 . Alternatively, control module 25 may communicate with a system controller for refrigeration system 5 and may notify system controller of the flood back or overheat condition. System controller may then adjust expansion valve or compressor speed accordingly.
[0050] DSH may be monitored to detect or predict a sudden flood back or overheat condition. A sudden reduction in DLT or DSH without significant accompanying change in Tcond may be indicative of a sudden flood back or overheat condition. For example, if DLT or DSH decreases by a predetermined temperature amount (e.g., fifty degrees Fahrenheit) within a predetermined time period (e.g., fifty seconds), a sudden flood back condition may exist. Such a condition may be caused by expansion valve 14 being stuck open. Likewise, a sudden increase in DLT or DSH with similar magnitude and without significant accompanying change in Tcond may be indicative of a sudden overheat condition due to expansion valve 14 being stuck closed. For example, if DLT or DSH increases by a predetermined temperature amount (e.g., fifty degrees Fahrenheit) within a predetermined time period (e.g., fifty seconds), a sudden overheat condition may exist.
[0051] Control module 25 may monitor DSH and DLT to determine whether compressor 10 is operating within a predetermined operating envelope. As shown in FIG. 7 , a compressor operating envelope may provide maximum flood back and maximum and/or minimum DSH/DLT limits. In addition, a maximum scroll temperature limit (Tscroll) may be provided, in the case of a scroll compressor. In addition, a maximum motor temperature (Tmotor) may be provided. As shown in FIG. 7 , compressor speed and expansion valve 14 may be adjusted based on DSH and/or DLT to insure compressor operation within the compressor operating envelope. In this way, DSH and/or DLT may move back into an acceptable range as indicated by FIG. 7 . Compressor speed adjustment may take priority over expansion valve adjustment. In some cases, such as a defrost state, it may be difficult for expansion valve 14 to respond quickly and compressor speed adjustment may be more appropriate.
[0052] In the event of a flood back condition, control module 25 may limit a compressor speed range. For example, when DSH is below thirty degrees Fahrenheit, compressor operation may be limited to the compressor's cooling capacity rating speed. For example, the cooling capacity rating speed may be 4500 RPM. When DSH is between thirty degrees Fahrenheit and sixty degrees Fahrenheit, compressor operating speed range may be expanded linearly to the full operating speed range. For example, compressor operating speed range may be between 1800 and 7000 RPM.
[0053] The function correlating Tcond with compressor speed and power, may assume a predetermined or constant saturated Tevap. As shown in FIG. 8 , the correlation between compressor power and Tcond may be insensitive to variations of Tevap.
[0054] For additional accuracy, Tevap may be derived as a function of Tcond and DLT, as described in commonly assigned U.S. application Ser. No. 11/059,646, U.S. Publication No. 2005/0235660. For variable speed compressors, the correlation may also reflect compressor speed. In this way, Tevap may be derived as a function of Tcond, DLT and compressor speed.
[0055] As shown in FIG. 9 , Tevap is shown correlated with DLT, for various Tcond levels. For this reason, compressor map data for different speeds may be used.
[0056] Tcond and Tevap may be calculated based on a single derivation.
[0057] In addition, iterative calculations may be made based on the following equations:
[0000] T cond= f (compressor power,compressor speed, T evap) Equation 1:
[0000] T evap= f ( T cond,DLT,compressor speed) Equation 2:
[0058] Multiple iterations of these equations may be performed to achieve convergence. For example, three iterations may provide optimal convergence. As discussed above, more or less iteration, or no iterations, may be used.
[0059] Tevap and Tcond may also be determined by using compressor map data, for different speeds, based on DLT and compressor power, based on the following equations:
[0000] T evap= f (compressor power,compressor speed,DLT) Equation 3:
[0000] T cond= f (compressor power,compressor speed,DLT) Equation 4:
[0060] Once Tevap and Tcond are known, additional compressor performance parameters may be derived. For example, compressor capacity and compressor efficiency may be derived based on additional compressor performance map data for a specific compressor model and capacity. Such additional compressor map data may be derived from test data. For example, compressor mass flow or capacity, may be derived according to the following equation:
[0000] T evap= f (compressor speed, T cond,mass flow) Equation 5:
[0061] Mass flow may be derived according to the following equation:
[0000] Mass Flow= m 0+ m 1* T evap+ m 2* T cond+ m 3*RPM+ m 4* T evap* T cond+ m 5* T evap*RPM+ m 6* T cond*RPM+ m 7* T evap̂2+ m 8* T cond̂2+ m 9*RPM̂2+ m 10* T evap* T cond*RPM+ m 11* T evap̂2* T cond+ m 12* T evap̂2*RPM+ m 13* T evap̂3+ m 14* T evap* T cond̂2+ m 15* T cond̂2*RPM+ m 16* T cond̂3+ m 17* T evap*RPM̂2+ m 18* T cond*RPM̂2+ m 19*RPM̂3 Equation 6:
[0062] where m0-m19 are compressor model and size specific, as published by compressor manufacturers.
[0063] Compressor map data may be stored within a computer readable medium within control module 25 or accessible to control module 25 .
[0064] As shown in FIG. 10 , a flow chart for derived parameters is shown. In step 100 , Tcond may be derived from compressor power and compressor speed. In step 101 , Tevap may be derived from DLT and Tcond. In step 102 , capacity/mass flow and a compressor energy efficiency ratio may be derived from Tevap and Tcond. In addition, by monitoring run time in step 103 , additional parameters may be derived. Specifically, in step 104 , load and Kwh/Day may be derived from run time, capacity/mass flow, EER, and compressor power.
[0065] By monitoring the above operating parameters, control module 25 may insure that compressor 10 is operating within acceptable operating envelope limits that are preset by a particular compressor designer or manufacturer and may detect and predict certain undesirable operating conditions, such as compressor floodback and overheat conditions. Further, control module 25 may derive other useful data related to compressor efficiency, power consumption, etc.
[0066] Where compressor 10 is driven by a suction cooled inverter drive 22 , Tevap may be alternatively calculated. Because Tevap may be calculated from mass flow, Tcond, and compressor speed as discussed above, control module 25 may derive mass flow from a difference in temperature between suction gas entering cold plate 15 (Ts) and a temperature of a heat sink (Ti) located on or near inverter drive 22 . Control module 25 may calculate delta T according to the following equation:
[0000] delta T=Ts−Ti Equation 7:
[0067] Ts and Ti may be measured by two temperature sensors 33 and 34 shown in FIG. 11 . Temperature sensor 33 measures the temperature of the heat sink (Ti) and may be incorporated as part of inverter drive 22 . Alternatively, temperature sensor 33 may measure a temperature of suction gas exiting cold plate 15 and may be located on or near the piping between cold plate 15 and compressor 10 . Temperature sensor 34 measures the temperature of suction gas entering cold plate 15 .
[0068] Control module 25 may determine mass flow based on delta T and by determining the applied heat of inverter drive 22 . As shown in FIG. 12 , mass flow may be derived based on lost heat of inverter drive 22 and delta T. As shown in FIG. 13 , the relationship between mass flow, delta T and applied inverter heat may be mapped based on test data.
[0069] Inverter heat may be derived based on inverter speed (i.e., compressor speed) and inverter efficiency as shown in FIG. 14 .
[0070] With reference again to FIG. 12 , inputs include compressor speed (RPM) 120 , compressor current 122 , compressor voltage 124 , compressor power factor 126 , Ti 128 and Ts 130 . From compressor current 122 , compressor voltage 124 , and power factor 126 , compressor power 132 is derived. From temperatures Ti 128 and Ts 130 , delta T 134 is derived. From RPM 120 and power, Tcond 136 is derived. Also from RPM 120 and power 132 , inverter heat loss 138 is derived. From inverter heat loss, and delta T 134 , mass flow 140 is derived. From RPM 120 , Tcond 136 , and mass flow 140 , Tevap 142 is derived. From Tevap 142 and Ts 130 , SSH 144 is derived. From SSH 144 and ambient temperature as sensed by ambient temperature sensor 29 , DSH 146 is derived. Once DSH 146 is derived, all of the benefits of the algorithms described above may be gained, including protection of compressor 10 from flood back and overheat conditions.
[0071] As shown by dotted line 141 , Tcond and Tevap may be iteratively calculated to more accurately derive Tcond and Tevap. For example, optimal convergence may be achieved with three iterations. More or less iterations may also be used.
[0072] As shown in FIG. 15 , control module 25 takes as measured inputs compressor speed RPM, inverter drive current, voltage, and power, and heat sink temperatures Ti and Ts. Control module also takes as input ambient temperature as indicated by ambient temperature sensor 29 . As discussed above, control module 25 derives from these measured inputs the outputs of Tcond, Tevap, mass flow, SSH, DSH, and DLT.
[0073] As shown in FIG. 16 , control module 25 may monitor SLT with SLT sensor 35 , which may include a combination pressure and temperature sensor may be used. In such case, Tevap may be measured based on the suction pressure as measured by the pressure portion of the combination sensor. Further, SSH may be calculated based on SLT, as measured by the temperature portion of the combination sensor, and Tevap. SLT sensor 34 , 35 may be located at an inlet to compressor 10 and may sense a temperature or pressure of refrigerant entering compressor 10 subsequent to inverter 22 , enclosure 20 , or cold plate 15 . Alternatively SLT sensor may be located at an inlet to enclosure 20 , inverter 22 , or cold plate 15 and may sense a temperature or pressure of refrigerant entering the enclosure 20 , inverter 22 , or cold plate 15 .
[0074] In addition, similar to the calculation of DSH based on DLT described above, control module 25 may also calculate SSH. For example, compressor power, compressor speed, and compressor map data may be used to derive Tcond and Tevap may be derived from Tcond. Once Tevap is derived, SSH may be derived from SLT and Tevap and used as described above for monitoring various compressor operating parameters and protecting against flood back and overheat conditions.
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A system and method for a compressor includes a compressor connected to a condenser, a discharge line temperature sensor that outputs a discharge line temperature signal corresponding to a discharge line temperature of refrigerant leaving the compressor, and a control module connected to the discharge line temperature sensor. The control module determines a saturated condenser temperature, calculates a discharge superheat temperature based on the saturated condenser temperature and the discharge line temperature, and monitors a flood back condition of the compressor by comparing the discharge superheat temperature with a predetermined threshold. The control module increases a speed of the compressor or decreases an opening of an expansion valve associated with the compressor when the discharge superheat temperature is less than or equal to the predetermined threshold.
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PRIORITY CLAIM
This application claims the benefit of previously filed U.S. Provisional Patent Application entitled “FIELD RETROFITTABLE REFRIGERATOR LOCK WITH TEMPERATURE MONITORING, TEMPERATURE BASED ACCESS CONTROL AND ALARMING,” assigned U.S. Ser. No. 60/988,903, filed Nov. 19, 2007, and which is incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
The present subject matter is directed toward secured storage refrigeration. More particularly, the present subject matter is directed to the secure storage and tracking of refrigerated, temperature sensitive medications, narcotics, vaccines and chemicals.
BACKGROUND OF THE INVENTION
In a typical application, various temperature sensitive refrigerated medications, narcotics, vaccines and chemicals (hereafter collectively referred to as medications) are stored in small refrigerators at nurses' stations in a hospital. Small refrigerators are not typically designed for security and are therefore not generally provided with any type of locking mechanism. New requirements set forth by the Joint Commission on Accreditation of Healthcare Organizations (JCAHO) as well as the ever-increasing needs for security are dictating the need to secure and track temperature sensitive medications, particularly narcotics.
As is known in the medical profession, certain medications may be temperature sensitive and may be rendered unfit for use if not maintained within a given temperature range. Under such conditions, therefore, a need exists not only to secure these medications but to also continuously monitor the temperature at which they are stored. There are a number of reasons that can cause temperature variations to occur. These reasons include, but are not limited to: power failure, refrigerator malfunction, or improper securing of the refrigerator door after access. Given the severe consequences, such as a medication becoming ineffective or dangerous after such an event, it is essential that any responsible party (such as, including nurses, doctors, and others) be made aware of any such event. Additionally, if such an event does occur, they may become a need or a desire to provide alarm functionality and/or restricted access to potentially unsafe medications.
As different medications have various recommended temperature ranges and associated tolerances for storage outside such ranges, the need exists for temperature monitoring and access control system functionality that may be fully programmable. Programmable adjustments which may be desired may include: settings of respective high and low temperature limits, settings of the permitted time period outside of such desired limits, settings of various alarms, and the setting of restricted access if certain limits are reached. For example, if a certain pre-programmed event were to occur, a refrigerator typically accessed by general users may become restricted to management level personnel only. The present temperature monitoring and access control system functionality would therefore have the potential to prevent the use of dangerous or ineffective medications.
While various implementations of secured refrigeration systems have been developed, and while various temperature responsive systems have been developed, no design has emerged that generally encompasses all of the desired characteristics as hereafter presented in accordance with the subject technology.
SUMMARY OF THE INVENTION
In view of the recognized features encountered in the prior art and addressed by the present subject matter, improved apparatus and methodology subject matters for controlling access to refrigerated storage areas have been developed.
In an exemplary configuration, a retrofittable motorized latch and an electronic access control circuit for use with small refrigeration systems have been provided.
In one of its simpler forms, a user interface and display is provided to permit convenient adjustment of system operational parameters.
Another positive aspect of the disclosed type of device is that operational parameters for the disclosed apparatus may be adjusted by way of a computer interface and accompanying software operating on, for example, a personal computer.
In accordance with aspects of certain embodiments of the present subject matter, methodologies are provided, upon occurrence of operational conditions potentially detrimental to materials stored within the refrigerated storage space, to limit access to refrigerated storage space to only those individuals with supervisory access authorization.
In accordance with certain aspects of other embodiments of the present subject matter, methodologies have been developed to track access to a refrigerated storage space by recording user identification and access dates and times.
In accordance with yet additional aspects of further embodiments of the present subject matter, apparatuses and accompanying methodologies have been developed to record operating parameters of the refrigeration system.
According to yet still other aspects of additional embodiments of the present subject matter, apparatuses and methodologies have been developed to insure that access to the refrigerated storage space is denied even to authorized users in case of faulty operation of the refrigeration system.
One present exemplary apparatus relates to a refrigerated area access control system, comprising an access control circuit, a lock, a user interface, and a temperature transducer. Such lock is preferably configured to be unlocked by the access control circuit. Such user interface may be configured to provide user access to such access control circuit, which such temperature transducer may be coupled to such access control circuit and configured for placement within the refrigerated area.
With the foregoing exemplary embodiment, preferably such access control circuit may be configured to monitor the temperature within the refrigerated area and to respectively permit differentiated access to the refrigerated area by a first user having a first access level and a second user having a second access level. With such an arrangement, the first user is denied access to the refrigerated area when the temperature within the refrigerated area is not maintained within predetermined parameters.
In certain optional implementations of the foregoing embodiment, such user interface may be further configured to permit such second user to adjust system operational parameters comprising one or more of adding credentials for first users, deleting credentials for first users, and adjusting temperature based parameter settings.
With still further options, such a refrigerated area access control system may include a user readable display configured to display values representative of the temperature within the refrigerated area. Further such user interface may comprise a control panel configured to permit manual programming of operational characteristics of the access control circuit by observation of such user readable display. In still other optional configurations, such a refrigerated area access control system may further include a computer interface associated with such user interface, and a computer, with such computer preferably configured to permit such second user to adjust system operational parameters comprising one or more of adding credentials for first users, deleting credentials for first users, and adjusting temperature based parameter settings.
In various of the foregoing embodiments, such lock may comprise a motorized slam bolt latch. In other exemplary embodiments, such system may further include an alarm configured to be activated when the temperature within the refrigerated area is not maintained with such predetermined parameters. In others, a memory may be optionally associated with such access control circuit, with such circuit preferably configured to store in such memory a number of different valid credentials to be used to access such refrigerated area, an audit trail for each access to such refrigerated area, and data logging at predetermined time periods of temperature readings within such refrigerated area. Likewise, still further, such system may include a credential presentation device consisting of at least one of a key pad, an electronic card reader, a biometrics reader, and a computer interface.
It should be further understood that the various foregoing exemplary embodiments may involve a such refrigerated area comprising a refrigerator, with such access control system configured to be retrofittable to such refrigerator.
In other present exemplary embodiments, such refrigerated area access control system may optionally include a temperature modulator associated with the temperature transducer, which temperature modulator is configured to provide thermal shock protection for such thermal transducer.
It should be understood that the present subject matter equally pertains to corresponding methodology. One exemplary present method comprises a method of providing access to a refrigerated area. Such exemplary method may include providing an access control circuit; monitoring temperature variations within the refrigerated area, for maintenance of such temperature variations within selected predetermined parameters; providing respectively differentiated access to the refrigerated area to a first user having a first credential enabled access level and to a second user having a second credential enabled access level; and denying access to the refrigerated area by a first user if the temperature within the refrigerated area is not maintained within the selected predetermined parameters.
Present alternative embodiments of methodology may further optionally involve providing a user interface including a display and a control panel; and permitting the second user to add first user credentials, delete first user credentials, and adjust temperature based parameters. Other alternative features may involve providing an alarm signal when the temperature within the refrigerated area is not maintained within the selected predetermined parameters for a predetermined period. In other present alternatives, providing second user access may comprise providing a user interface including a computer interface; associating a memory with the access control circuit; storing temperature measurement data in the memory; and providing a computer configured to permit the second user to upload data to the memory to add first user credentials, delete first user credentials, and adjust temperature based parameters, and to download and display stored data.
Other present exemplary methodologies may alternatively involve monitoring access events by first and second users; and storing an audit trail of the access events in the memory.
Optionally, providing an access control circuit may include retrofitting such access control circuit to an existing refrigerated area.
Additional objects and advantages of the present subject matters are set forth in, or will be apparent to, those of ordinary skill in the art from the detailed description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referred and discussed features and elements hereof may be practiced in various embodiments and uses of the present subject matters without departing from the spirit and scope of the subject matter. Variations may include, but are not limited to, substitution of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like.
Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of the present subject matters may include various combinations or configurations of presently disclosed features, steps, or elements, or their equivalents (including combinations of features, parts, or steps or configurations thereof not expressly shown in the Figures or stated in the detailed description of such Figures). Additional embodiments of the present subject matters, not necessarily expressed in the summarized section, may include and incorporate various combinations of aspects of features, components, or steps referenced in the summarized objects above, and/or other features, components, or steps as otherwise discussed in this application. Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the remainder of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended Figures, in which:
FIG. 1 is an upper right isometric view of an exemplary representative refrigerator with the door thereof in a closed and locked position with a lock provided in accordance with the present technology installed thereon, and illustrating the door thereof in partial cutaway for illustration of various present features internal to such refrigerator;
FIG. 2 is a front elevation view of a refrigerator in accordance with the present technology and illustrating a lock with cover portions thereof removed and with a latch bolt thereof engaging a present exemplary strike plate;
FIG. 3A is a front elevation view of a refrigerator similar to that of FIG. 2 but partially illustrating internal components of an exemplary latch thereof with the latch bolt retracted;
FIG. 3B illustrates an isolate, enlarged view of a portion of exemplary lock illustrated in FIG. 3A , and illustrating in greater detail the retracted latch bolt thereof;
FIG. 4A is a front elevation view of a refrigerator having a lock installed thereon and illustrating a control panel including navigation keys for programming certain operational characteristics of the lock in accordance with the present technology, and illustrating the door thereof in partial cutaway for illustration of various present features internal to such refrigerator;
FIG. 4B is an enlarged portion of the control panel of present FIG. 4A , particularly illustrating exemplary navigation key features thereof;
FIG. 5 is a pictorial flowchart of exemplary manual programming menus available for programming certain operational aspects of an exemplary lock in accordance with present technology;
FIG. 6 is a screen capture of exemplary computer based programming menus alternatively available for programming certain operational aspects of the present lock in accordance with present technology;
FIG. 7 is an upper right isometric view of a present exemplary refrigerator similar to that as illustrated in FIG. 1 but illustrating the door thereof in an open and unlocked position;
FIG. 8A is a side elevation view of a present exemplary lock on an exemplary refrigerator with the lock bolt thereof hitting a present exemplary strike plate;
FIG. 8B is an enlarged view of a portion of the exemplary lock illustrated in FIG. 8A , showing in greater detail the present exemplary lock bolt hitting the subject strike plate;
FIG. 9A is a side elevation view of a present exemplary lock on an exemplary refrigerator similar to that as illustrated in FIG. 8A except the exemplary lock bolt has been pressed in by the subject strike plate;
FIG. 9B is an enlarged view of a portion of the exemplary lock illustrated in FIG. 9A , showing in greater detail the present exemplary lock bolt pressed in by the subject strike plate;
FIG. 10A is a side elevation view of a present exemplary lock on an exemplary refrigerator similar to that as illustrated in FIGS. 8A and 9A except the exemplary lock bolt is engaged in a rectangular cutout of the subject strike plate;
FIG. 10B is an enlarged view of a portion of the exemplary lock illustrated in FIG. 10A , showing in greater detail the present exemplary lock bolt engaged in a rectangular cutout of the subject strike plate;
FIG. 11 is an illustration of an exemplary computer generated output of a temperature data logging feature in accordance with present technology; and
FIG. 12 is an illustration of an exemplary computer generated output of an access data logging feature in accordance with present technology.
Repeat use of reference characters throughout the present specification and appended drawings is intended to represent same or analogous features, elements, or steps of the present subject matter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As discussed in the Summary of the Invention section, the present subject matter is particularly concerned with controlling access to refrigerated storage areas.
Selected combinations of aspects of the disclosed technology correspond to a plurality of different embodiments of the present subject matter. It should be noted that each of the exemplary embodiments presented and discussed herein should not insinuate limitations of the present subject matter. Features or steps illustrated or described as part of one embodiment may be used in combination with aspects of another embodiment to yield yet further embodiments. Additionally, certain features may be interchanged with similar devices or features not expressly mentioned which perform the same or similar function.
It should be specifically noted that while the present disclosure generally describes the lock disclosed herein as a retrofittable lock, such terminology should not be taken as a limitation of the present subject matter in any way as the presently disclosed lock may, indeed, be provided as original equipment.
The present subject matter relates in part to a motorized latch and an electronic access control circuit mounted within a plastic housing and provided as a retrofittable lock for a refrigerator. A user interface may be provided through an LCD display and control panel mounted on the face of the housing. Additionally, a temperature transducer which is continuously monitored by the electronic access control circuit is provided for installation within a temperature controlled compartment. The housing may be easily mounted to most small refrigerators in minimal time, with minimal tools, and without disassembly of the refrigerator. The temperature transducer and its associated wiring back to the control circuit are also easily installed within the refrigerator with minimal interference with the door seal. The main assembly mounts to the refrigerator door with tamper resistant sheet metal screws, double sided tape or by other appropriate securing means including, for example, pop-rivets. The motorized latch in the main assembly may engage a rectangular hole in the strike, preventing the refrigerator door from being opened.
The LCD display continuously displays current temperature within the controlled enclosure and in conjunction with the control panel allows changes to be entered to the temperature based programmable settings. Additionally, the unit functions to provide access control to the enclosure. The unit quickly unlatches upon presentation of a valid access credential by the user: typically a key pad entered PIN or electronic card. The control circuitry allows for a large number of different valid credentials to be used for access and has the ability to record each entry creating an “audit trail”. The “audit trail” consists of the card or PIN number that gained access as well as the date and time of access. A significant history can be developed limited only by the size of the memory chips in the controller.
The temperature transducer can be one of several different types including, but not limited to, thermistors and thermocouples. The function of the temperature transducer is to return a voltage to the control circuit proportional to the temperature of its environment. The control circuit then converts this voltage to the temperature value displayed by the LCD display and used in the temperature based programmable settings. An associated microprocessor may be pre-programmed with a conversion table that allows it to very accurately determine the temperature of the transducer environment. However, it is possible to adjust this table on a per-unit basis to provide additional accuracy, through calibration.
It may be desirable to modulate the temperature extremes experienced by the transducer caused by opening of the refrigerator door. This can be done by placing the transducer in a small bottle of fluid known to exhibit the thermal properties similar to most medications. This method of temperature modulation provides a “thermal shock absorber” and more accurately reflects the temperature of the stored medications.
Before entering service, the administrator of the temperature based access control system configures the system to the individual needs of the installation. That is, they set the: 1) highest acceptable temperature to which that medication can be exposed; 2) the lowest acceptable temperature to which that medication can be exposed; 3) the maximum amount of time that the medication can be outside of the “temperature window” set in 1) and 2); 4) whether or not to sound an alarm if the “temperature window” set in 1) and 2) is violated for a time exceeded by the setting in 3); 5) the alarm volume; 6) whether or not to sound a remote alarm, drawing attention to someone outside of the audible range of the system and finally; 7) whether or not to restrict access to supervisors once an alarm has sounded. Additionally users have the ability to choose between Fahrenheit or Celsius temperature display units and are provided with the ability to mute the alarming system.
The temperature based access control system also provides a data-logging feature. In other words, users will have the ability to view and download a temperature history of the refrigerator. This history can be viewed by pressing an “up” button on the keypad, which will display the maximum observed temperature; or by pressing a “down” button on the keypad, which will display the minimum observed temperature. The data can be logged in one minute increments with the size of the increment being set by the system administrator. In addition to viewing the max/min observed temperatures, the system is provided with the ability to connect a personal computer (PC) and download the data containing the historical temperature record of the enclosure. This data can be viewed in the raw state, or processed into a chart providing the user with a “strip chart” style reading of temperature versus time. The scales of the charting are adjustable by the user. There are additional data manipulations features, well understood by those of ordinary skill in the data processing art without requiring additional detailed discussion, including downloading to a database for manipulation by a spreadsheet style program.
An individual attempting access to the refrigerator will present their access control credential (PIN, magnetic stripe card, proximity card, biometric, etc) to the access control circuitry through a relevant reader. The access control circuitry compares the credential to a known list of valid credentials and determines validity. If the credential is valid and the temperature alarm is not active, access will be granted. If the alarm is active, access will only be granted to supervisors when this feature is enabled.
According to an exemplary embodiment of the present technology, a motor/gear train assembly may be used to retract a slam latch bolt. A gear motor housing is attached to the inside of the main lock housing, which is attached to the front of the refrigerator door. In the normal or locked state, a latching bolt protrudes from the top of the lock assembly engaging a strike plate mounted on top of the refrigerator. The interaction of the latching bolt and the strike plate prevents someone from surreptitiously gaining access to the refrigerator. When the slam latch bolt is drawn in, it is pulled out of the strike, which is attached to the top of the refrigerator, allowing the refrigerator door to be opened.
Operation of the lock may proceed as follows. For purposes of this description, the starting point will be with the refrigerator locked and a nurse attempting to enter the refrigerator to acquire narcotics. To begin the open cycle, the nurse enters a credential or presents a biometric to the electronic lock. The access control circuitry compares the credential (or biometric) to a known list of valid credentials or biometrics, respectively. If the credential or biometric is deemed valid, the access control circuitry then checks the status of the temperature alarm. If the alarm has sounded, (normally due to the fact that the temperature transducer has been outside of a preprogrammed set of temperature limits for a preprogrammed amount of time) the access control circuitry then checks if the credential presented is approved for entry under this alarm condition if such feature is so enabled.
In such exemplary embodiment, there are two access levels: user and supervisor. In other embodiments, additional or fewer access levels may be provided. The circuitry can be preprogrammed to deny normal users' access to the refrigerator after the alarm has sounded. In instances where an alarm has sounded, only supervisory level credentials will be permitted entry, reducing the chances that medications which may now be ineffective (due to incorrect storage temperature conditions) will be inadvertently used.
If the presented credential does not have supervisor status, the access control circuitry then communicates to the user through a display, beeper, LED or other suitable means that the alarm has sounded and only a supervisor can access the refrigerator. The system administrator has the option of allowing supervisor access only in the alarmed state or to continue to allow access to all users with valid credentials. Upon validation of access permission, the access control circuit will then energize the motorized latch, retracting the slam bolt into the latch housing, allowing the refrigerator door to be opened.
When the locking bolt is drawn into the motorized latch housing, it is also drawn into the main lock assembly. The latching bolt may be spring loaded by a return spring, biasing the latching bolt out of the motorized latch housing. Such action removes the blocking interaction between the latching bolt and the strike plate, allowing the nurse (or other authorized entrant) to open the refrigerator.
The latching bolt remains drawn into the motorized latch housing for a programmable amount of time allowing the nurse (or other authorized person) to open the refrigerator door and gain access to the contents of the refrigerator. In an exemplary embodiment, the programmable amount of time may correspond for example to five seconds. Upon expiration of the open delay timer, the motorized latch releases the latching bolt. It then re-extends out of the latch housing and out of the main assembly housing. The latching bolt is now in position to re-lock the refrigerator door upon its closing.
When the nurse has completed accessing the refrigerator, the nurse will slam the refrigerator door. This action will cause the latching bolt to hit the strike plate. The end of the latching bolt and the end of the strike plate are each provided with cam surfaces which cause the latching bolt to push into the motorized latch housing when the refrigerator door is closed. When the latching bolt pushes into the motorized housing, the return spring is again charged. The strike plate is provided with a rectangular cutout section, located just past the cam surface, which is designed such that the latching bolt will enter it as the refrigerator door closes.
After the latching bolt is pushed into the motorized latch housing and the door continues to close, the tip of the latching bolt travels on the bottom of the strike plate for some distance. Eventually, the tip encounters the rectangular cutout on the strike plate and the charged spring on the latching bolt causes it to re-extend from the motorized latch housing, entering the rectangular cutout section of the strike, and locking the refrigerator (or, that is, the door of the refrigerator). The microprocessor then records the event, recording the card/pin number that accessed the refrigerator as well as the date and time. In an alternative configuration, the microprocessor may be configured to record events including card/pin number and time and date at the time access occurred in place of or in addition to recording at door closure. Recording data upon initial access would preclude possible loss of access data if the refrigerator door remains open accidentally or intentionally.
As described above, there are numerous settings for the temperature monitoring and access control systems. These include (but are not limited to) temperature limit settings, alarm status, supervisor status required for entry after alarm settings, as well as the list of valid credentials or biometrics. In accordance with the present subject matter, such settings can be made through a control panel on the front of the system, or through a PC based access control system.
Using the front panel programming method, the access control system requires the lock to be accessed by a supervisor first. Once supervisor access has been performed, there are three menu systems that can be accessed: add valid credentials, delete valid credentials and temperature based settings. The add valid credentials menu has the option of simply teaching the system valid credentials, by credential presentation, (allowing the system to choose the memory location) or by having the user tell the access control into which memory location to put a valid credential. In accordance with an exemplary embodiment, 250 different memory locations may be provided, but such number can easily be expanded (or reduced) by those skilled in the art, as desired. Therefore, the details of such aspect of such feature form no particular aspect of the present subject matter.
Deleting selected valid credentials is just as simple with a delete valid credentials menu. Such menu also has the option of simply teaching the system invalid credentials, by invalid credential presentation. Clearing of invalid credentials may be achieved by allowing the system to find the memory location in which the invalid credential resides, and clearing it, or by having the user tell the access control which memory location to clear. It is preferred, although less convenient, to tell the lock which memory location to clear, as the invalid credential is not needed to perform such programming. Typically, the credential that the user wants to invalidate is not available to re-present to the lock due to the fact that it is lost or in the possession of the person for whom it is desired that access no longer be provided.
The third front panel menu system that can be accessed after a valid supervisor access is the temperature based settings menu. Such menu allows the supervisor to enable the alarm, set the high temperature limit, set the low temperature limit, choose the units of measure (Fahrenheit or Celsius), silence an alarm which is currently active, or reset the observed maximum or minimum temperature settings. Such programming system is menu based, allowing the supervisor to first choose which setting to adjust, and then to set the new value.
It may be simpler (although sometimes less convenient, as a PC is required) to use a PC based access control system to provide desired settings. Using a PC system, valid credentials may be easily stored, access rights assigned between desired users and locks, and information easily uploaded into the lock. Such a system may be provided to allow easy setting and uploading of the previously described temperature based settings. In addition to such settings, the supervisor can also set the required access level in the event of a sounded alarm. If set, such will require a user to have supervisor status in order to access a lock system which is alarming.
Additionally, the system in accordance with the present subject matter has been configured to provide data logging. In other words, the temperature based circuitry can be set to not only monitor the ambient temperature of the temperature transducer, but also to store observed settings. The frequency of such recordings can be set in integer multiples of minutes, as low as one minute. It is further possible to set the logging frequency to be different if the alarm is sounding or not. For example, the supervisor can set up the system to log the temperature every 10 minutes if the temperature is within the desired operating window and every 2 minutes if it is outside of such window.
The program also has the ability to download the logged data and display it in graphical form. Such functionality will provide a virtual strip chart (observed temperature with respect to time) that the supervisor can use. The scales of the strip chart are easily adjustable depending on the supervisor's needs or preferences. Finally, the hard data can be exported into a text file for manipulation within a spreadsheet.
Reference will now be made in detail to the presently preferred embodiments of the subject refrigerator lock. Referring now to the drawings, FIG. 1 illustrates an upper right perspective of a refrigerator 13 b with the door in the closed and locked position with a lock 13 a in accordance with the present technology installed thereon. Lock 13 a includes a main housing 13 c , electronic assembly 14 a , battery pack 14 b , communications port 14 c , and programming keypad and display 15 . Lock 13 a is attached to refrigerator 13 b with a plurality of screws collectively and representatively noted as screw 17 . Lock 13 a is configured to engage a strike assembly 18 a that, when properly positioned, keeps the refrigerator locked. Strike assembly 18 a may be attached to refrigerator 13 b by screws or by other appropriate means including, but not limited to, pop-rivets, double sided tape, adhesives, and welding. As illustrated with the partial cutaway of the door of refrigerator 13 b , electronic assembly 14 a is electrically connected to thermistor assembly 16 a by way of cable 16 b.
With reference now to FIG. 2 , there is illustrated a front elevation view of a refrigerator 13 b in accordance with the present technology and illustrating a lock 13 a with cover portions removed and the latch bolt 22 engaging a strike plate 23 a . A back cover 23 b , shown for reference purposes, may be attached to main housing 13 c with screws (not illustrated) or by other appropriate means. Motorized latch assembly generally 20 is attached to main housing 13 c with a plurality of screws 21 exemplarily and representatively noted by screw 21 . Latch assembly 20 is provided with latch bolt 22 which engages an opening in strike plate 23 a in the locked position to keep refrigerator 13 b locked. Strike plate 23 a is attached to the top of the refrigerator with mounting screws (not illustrated) and may be provided with a cover 23 b which may be attached to strike plate 23 a with a plurality of screws 18 b or by other appropriate means.
With reference to FIGS. 3A and 3B , there are illustrated, respectively, a front elevation view of a refrigerator 13 b illustrating internal components of motorized latch 20 with latch bolt 22 retracted, and an enlarged view of a portion of such lock illustrating retracted latch bolt 22 . Those of ordinary skill in the art will appreciate that in accordance with broader aspects of the present subject matter, various mechanisms can be used to accomplish the same end result, i.e., the retraction of bolt 22 into the motorized latch 20 , and that the illustrated mechanism corresponds to an exemplary such method and related apparatus.
The prime mover in motorized latch 20 is motor 24 . In an exemplary embodiment, a permanent magnet DC motor may be used. However, various types of motors may be employed, per the broader aspects of the present subject matter. Motor 24 may be provided in conjunction with gear train 25 a that moves mechanism 25 b , which in turn retracts latch bolt 22 into latch 20 . When latch bolt 22 is retracted, the blocking interaction of latch bolt 22 with strike plate 23 a is removed, as shown in greater detail with reference numeral 90 in enlarged FIG. 3B .
With reference to FIG. 4A , there is illustrated a front elevation view of a refrigerator 13 b having a lock 13 a installed thereon and illustrating an electronics assembly 14 a including a control panel 15 and navigation keys 26 a , 26 b , 26 c , and 26 d for programming certain operational characteristics of the lock in accordance with the present technology. FIG. 4B illustrates an enlarged portion of such exemplary control panel 15 , particularly illustrating the navigation keys 26 a , 26 b , 26 c , and 26 d and display 27 . It is to be understood that the broader aspects of the present subject matter encompass various placements of such navigation keys and display relative to each other.
Motor 24 ( FIG. 3B ), and thereby latch bolt 22 , is operated per present subject matter preferably under the control of a microprocessor based circuit (or equivalent) located within electronics assembly 14 a . In accordance with the illustrated exemplary embodiment of the present technology, electronics assembly 14 a receives input from a user attempting to gain access to the refrigerator 13 b via the keypad 14 d of electronics assembly 14 a ( FIGS. 1 and 4A ). It should be appreciated by those of ordinary skill in the art that a variety of different types of access control credentials may be used instead of or in addition to the electronics assembly 14 a . Such credentials may include, but are not limited to, proximity cards, magnetic stripe cards, smart cards, RF fobs, IR fobs, and Dallas semiconductor i-Buttons, as well as a plethora of biometric type access control technologies available to industry.
When the electronics assembly 14 a receives data, in this exemplary case a personal identification number (PIN) from a user, the electronics assembly 14 a processes the PIN and determines the validity of the code. Typically, electronics assemblies of this type will have a number of available valid codes. In accordance with an exemplary embodiment, 250 valid codes may be provided. It should be appreciated, however, that such number is a design limitation determined primarily by specific needs associated with a particular installation of lock model and the amount of memory installed in the device, as opposed to being a limitation of the present subject matter.
The electronics assembly 14 a is configured to compare an entered PIN (or other coded identification) to its list of preprogrammed valid codes. If the code is determined to be valid and the temperature alarm is not currently active, access is granted and the electronics assembly 14 a turns on motor 24 . If the alarm is active, access will only be granted to supervisors when such feature is enabled. The alarm function can be programmed manually (as is otherwise described herewith reference to FIG. 5 ), or through a personal computer (PC) based program (as otherwise described with reference to FIG. 6 ).
With further reference to FIG. 4A , it will be seen that the front of the lock assembly 13 a includes in the illustrated exemplary configuration a keypad 15 . Keypad 15 , illustrated in enlarged detail in FIG. 4B , is provided with a back button 26 a , an enter button 26 b , a down button 26 c , an up button 26 d , and a display 27 . In an exemplary embodiment, display 27 may correspond to an LCD display; however, other types of displays may also be employed. Such buttons and the display are used to navigate a menu based programming scheme. The programming scheme is used to select or unselect various programming options within a lock constructed in accordance with the present technology. Such programming menu can only be accessed by persons (hereafter referred to as a “supervisor”) who have a relatively higher level of security access than that of the typical user.
With reference now to FIG. 5 , there is illustrated a pictorial flowchart of the manual programming menus (programming “tree”) available for programming certain operational aspects of the lock in accordance with present technology. Navigation of the programming tree is accomplished using the enter button 26 b ( FIG. 4B ) to go one level deeper into the tree or to accept a setting if you are at the end of a tree “branch”, the back button 26 a to go one level higher in the tree, the up button 26 d to scroll up through the options available at the current tree level, and the down button 26 c to scroll down through the options available at the current tree level.
The images illustrated in FIG. 5 represent those as may be displayed on exemplary LCD display 27 . These images, of course, are limited to the number of characters on the display but those of ordinary skill in the art could easily employ other display technologies (for example LED based displays and TFT displays) limited only by the scope of the desired cost. For clarification purposes with reference to the following discussion, any words that appear as abbreviations on the illustrated display will be discussed without abbreviation. For example, point 31 reads “St Time” which is abbreviated for “Set Time” and would be referred to as such.
As previously noted an individual assigned a higher level of security, referred to as the supervisor, enters their PIN number into the electronics assembly 14 a (and/or shows a credential or biometric) and if the credential is a valid supervisor credential, the menu illustrated in FIG. 5 can be accessed, at point 28 . The supervisor can then scroll between three options: alarm 29 , units 30 , and set time 31 . If the supervisor chooses alarm 31 , the alarm branch of the menu tree is entered.
The alarm branch 29 consists of two main paths, one (shown by reference numeral 47 ) if the alarm was enabled when the supervisor entered the programming tree, and one (shown by reference numeral 46 ) if the alarm was not enabled (i.e., the alarm is disabled) when the supervisor entered the programming tree. For purposes of this discussion, first we will assume the alarm was disabled when the supervisor entered the programming tree, therefore we will begin at the tree branch noted by reference numeral 46 .
If the supervisor wishes to enable the alarm, they will be prompted with the enable prompt 32 . If the supervisor then enables the alarm by pressing enter 26 b , the following options are available: limits 33 , disable 34 , alarm volume 35 , mute 36 , and reset 37 . Such options are easily scrollable with the up button 26 d and the down button 26 c . When the desired option is reached, the supervisor presses enter 26 d.
The limits option 33 allows the supervisor to set the temperature window in which the alarm will not sound. Typically, this is the maximum and minimum temperature at which narcotics or vaccines can safely be stored without damage. Once the limits option 33 is chosen, the supervisor selects the minimum temperature 38 and the maximum temperature 39 . The desired temperatures can be entered directly on the keypad on the electronics unit 14 a or may be scrolled with the up 26 d and down 26 c arrows.
The disable option 34 allows the supervisor to silence the temperature alarming features. The alarm volume option 35 allows the supervisor to choose the relative alarm volume: loud, medium or soft 40 . The mute option 36 allows the supervisor to temporarily turn off the alarming feature. Such may be desirable in certain instances, for example, as the medium and loud settings can be disrupting in a noise sensitive environment (i.e., hospital, doctor's office, etc.).
The temperature monitoring system has the ability to display the minimum and maximum temperatures recorded since the last time such feature was reset. Typically, the person in charge of the temperature of the narcotics can see the minimum temperature (since last reset) by pressing the down button 26 c and the maximum temperature (since last reset) by pressing the up button 26 d . If the supervisor desires to reset such option, they choose the reset option 37 . As it is not possible to “undo” this choice, the supervisor must confirm this selection at step 41 .
If the alarm was already enabled when the supervisor entered their credential and they entered the alarm branch at point 29 , the menu will follow the path generally noted by branch 47 . Such branch is very similar to branch 46 except that the alarm does not need to be enabled first, as it is already on. Once the operator chooses the alarm branch 47 , the following options are available: limits 50 , disable 51 , alarm volume 52 , mute 53 , and reset 54 . Such options are easily scrollable with the up button 26 d and the down button 26 c . When the desired option is chosen, the supervisor presses enter 26 d.
The limits option 50 behaves exactly as previously described, choosing the minimum alarming temperature at step 55 and the maximum temperature at step 56 . The disable option 51 behaves as previously described. The alarm volume option 52 behaves as previously described, allowing the supervisor to choose the relative alarm volume: loud, medium or soft 57 . The mute option 53 behaves as previously described. The reset option 54 behaves as previously described with the confirmation at step 58 .
Returning to the original options presented to the supervisor after entering their credential, it will be seen that there are two other options available, aside from alarm based options 46 , 47 . They are units 30 and set time 31 . Units option 30 allows the supervisor to choose Fahrenheit or Celsius as the unit of temperature measure. Such selection is performed at step 59 . The set time option 31 allows the supervisor to set the year, month, date, hour and minute at step 60 .
The programming menu tree just described can typically only be entered by a supervisor, that is, an individual assigned a relatively higher level of security (authorization) clearance. There are circumstances, however, where it might be desirable to allow persons with relatively lower security clearance (hereafter called a “user”) to perform some or all of such programming features. Further, there are additional features that do not lend themselves to simple programming with a small LCD display and four buttons. It will be appreciated by those of ordinary skill in the art that manufacturing products at a higher cost level could easily integrate additional features and selections into the subject manual programming tree, given an understanding of the present subject matter as herein described. All such variations are intended to come within the scope of the presently disclosed subject matter.
In accordance with the present technology, a personal computer (PC) based program may be employed to provide additional optional programming capabilities, as illustrated and represented in FIG. 6 . FIG. 6 illustrates a screen capture of an input portion of an exemplary PC based program that may be employed in accordance with present technology to program selected lock related options. Such screen is divided into an upper section called user permissions 80 , a middle section called temperature/alarm settings 81 , and a lower section called logging frequency 82 .
The user permissions section 80 is used to select which options in the previously described programming tree are open to supervisors and which are open to users. The column of check boxes generally referred to with reference numeral 61 denote which options are available to users. The presence of a check mark in this example denotes that users can use the corresponding option and the absence of a check mark in this example denotes that users cannot use the corresponding option. Similarly, the column of check boxes generally referred to with reference numeral 62 denote which options are available to supervisors. The presence of a check mark denotes that supervisors can use the corresponding option, and the absence of a check mark denotes that supervisors cannot use the corresponding option.
In the exemplary configuration of the present technology illustrated herein, eight selectable options are illustrated. It will be appreciated by those of ordinary skill in the art, however, that such available options could be increased or decreased, all within the overall scope of the present subject matter. Such exemplary options include the ability to reset the minimum and maximum observed temperatures 63 . Such reset option corresponds to previously discussed manual programming steps 37 and 54 . A number of additional options have similar correspondence to previously discussed manual programming steps. Thus, high and low temperature limits 64 correspond to previously discussed manual programming steps 33 and 50 ; the ability to mute the alarm 65 corresponds to manual programming steps 36 and 53 ; the ability to set the volume of the alarm 66 corresponds to manual programming steps 35 and 52 ; the ability to enable and disable the alarm 67 corresponds to manual programming steps 32 , 34 and 51 ; the ability to set the units of temperature measure (Fahrenheit or Celsius) 68 corresponds to manual programming step 59 ; and the ability to set the date and time 69 corresponds to manual programming steps 31 and 60 .
A final exemplary setting option is not available for manual selection in this exemplary configuration. Typically, after a user or supervisor enters their credential, the electronic locking mechanism opens and allows access to the refrigerator. There are instances, however, where additional attention needs to be drawn to the fact that the electronics are in the alarming state (the case where extremely critical vaccines are being stored, for example). Such option can be selected in row 70 . If the user box is checked, users will be allowed to access an alarming system. If it is not selected, they will not be able to access the refrigerator. In the case of a supervisor, if the supervisor box is not selected, they will be forced to MUTE the alarm before gaining access.
Turning now to the middle section 81 of the PC based programming screen, it will be seen that the exemplary actual temperature and alarm settings are displayed. The high temperature alarm setting is shown at point 71 and the low temperature setting is shown at point 72 . Such values can be easily highlighted and changed. The units of measure will be displayed per those previously selected, either Fahrenheit 73 a or Celsius 73 b .
There might be the need to delay for some amount of time the alarm sounding after the thermistor 16 a has experienced temperatures outside the temperature window set at points 71 and 72 . If the operator of the PC program wishes to add such delay, they may do so at points 74 and 75 .
The selection box noted by reference numeral 76 illustrates whether or not the alarm is currently enabled. The operator of the program has the ability at this point to change the setting. The pull down menu noted by reference numeral 77 illustrates the current volume setting. The operator of the program has the ability at this point to change the setting.
The PC based program has the ability to log or record the temperatures observed at the thermistor 16 a . The frequency (in minutes) is shown and selected in the lower section 82 of the PC based programming screen. The operator can choose the amount of time between recorded temperature measurements while the recorded temperature is inside the temperature window chosen at points 78 and 79 and while outside such window. Typically, the operator will want more accurate (higher resolution) data when the refrigerator is outside the window. The frequency inside the temperature window, denoted as “when in range”, is illustrated and adjustable at point 78 . The frequency outside the temperature window, denoted as “when out of range”, is illustrated and adjustable at point 79 . Such reporting of the recorded data will be otherwise discussed with reference to FIG. 11 .
Further considering how a refrigerator opens in accordance with present subject matter, it is understood that the microprocessor processes all of the above information, whether entered manually or by the PC program, and based upon the person's security level and the current state of the temperature monitoring system, the locking system will release.
With reference again to FIG. 3 , the lock system will now be discussed in the unlocked state. Motor 24 will remain in the un-energized state while the processor times out a pre-programmed open time. Latch bolt 22 will be in the retracted position, which creates gap 90 between latch bolt 22 and strike plate 23 a . Such gap 90 allows the person who is attempting to gain access to the refrigerator the means to do so. As illustrated now in FIG. 7 , the refrigerator is open, as shown by representative gap 91 .
In summary, motor 24 is under the control of the microprocessor based circuit within the electronic assembly 14 a . As shown in FIG. 3 , the electronic assembly opens the motorized latch by turning on motor 24 . Internal to latch 20 (and not shown for simplicity sake), there is a feedback switch which senses that the latch bolt 22 is fully retracted. When the latch bolt 22 is fully retracted, motor 24 is turned off. The microprocessor keeps the motor turned off for a pre-programmed open time. When such open time timer times out, the processor again energizes motor 24 , which releases latch bolt 22 . In such state, latch bolt 22 is free to travel in and out of the motorized latch, charging and re-charging the slam bolt return spring.
Such slam-latch action is needed to automatically lock the refrigerator when the person that gained access to the refrigerator closes the door. Such action is illustrated in FIGS. 8A , 8 B, 9 A, 9 B, 10 A, and 10 B. First, with reference to FIGS. 8A and 8B , the beginning of the latch relocking action is illustrated. When the refrigerator door is closed, latch bolt 22 comes into contact with strike plate 23 a at point 93 . Such action begins to push latch bolt 22 into the motorized latch 20 and, therefore, begins to charge a slam bolt return spring (not illustrated). The next stage of an exemplary present re-locking event is illustrated in FIGS. 9A and 9B , which show latch bolt 22 further entering motorized latch 20 .
The final stage of the present exemplary re-locking event is shown in FIGS. 10A and 10B , where the latch bolt 22 enters opening 94 of strike plate 23 a . The charged slam bolt return spring then causes the latch bolt 22 to extend into strike plate opening 94 .
At such time, if someone is attempting to gain unauthorized access to the refrigerator by opening the door, the latch bolt will crash into the front wall of strike plate opening 94 at wall 95 . Since the motorized latch 20 is connected to main housing 13 c with screws 21 and main housing 13 c is connected to refrigerator door with screws 17 , and strike plate 23 a is secured to the top of the refrigerator with screws, the door of refrigerator 13 b will not open.
The temperature data that is recorded by the microprocessor at the logging frequencies set at points 78 and 79 can easily be downloaded through communications port 14 c and displayed as part of the same PC program discussed in FIG. 6 . The data can be displayed numerically, that is “38 degrees Celsius at 10:22 am Jun. 22, 2007” or graphically as a plot of temperature vs. time. Sample output from the graphical output screen is shown is FIG. 11 .
The operator of the software chooses which temperature based monitoring system to view the corresponding data from in pull down menu 100 . The graph is shown in graph area 101 , which has time for an X axis. The corresponding X axis values are shown by reference numerals 105 (illustrating the far left time value Jul. 2, 2007 2:24 pm) and 106 (illustrating the far right time value Jul. 3, 2007 2:24 pm). The Y axis in this example is temperature. The temperature values in Celsius are shown on the left side at reference numeral 103 and on the right side in Fahrenheit at reference numeral 104 . The actual graph of temperature vs. time in this example is shown by reference numeral 102 . The time axis can be moved right (earlier in time) or left (later in time) by control buttons 109 a , 109 b , 109 c , and 109 d . The size (in time) of the overall window can be changed by pull down 107 . For example, it might be advantageous to see temperatures for 3 months on the computer screen or 1 hour, depending on the individual operator needs. The Y axis scale can be selected by pull down 108 .
Finally, the operator can view the actual temperature and time data in report format by pressing button 110 . The output that is created by pushing such button is illustrated in FIG. 12 . Column 120 shows the lock serial number, column 121 shows the event time, column 122 shows the recorded temperature, column 123 illustrates the time that the data was retrieved from the lock.
While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
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Disclosed are apparatus and methodology subject matters for temperature monitoring and controlled access to refrigerated medications. An electronically controlled lock is installed on a refrigerator used for storage of temperature sensitive medications. Lock access is given to individuals having differing levels of access authorization so that user level authorization holders may have access to stored medications. Supervisor level authorization holders may have access to stored medications and may also effect changes in lock settings including setting alarm levels. Alarm levels may be adjusted to monitor temperatures within the refrigerated storage area so that in the case that temperature fall outside preset limits, access to the stored medicines may be had only by those individuals having supervisory access authorization.
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CROSS-REFERENCE TO RELATED APPLICATIONS
None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
The invention relates to a method for improving the Bayer process for the production of alumina from bauxite ore. The invention concerns the use of cross-linked polysaccharides, specifically cross-linked dextran or cross-linked dihydroxypropyl cellulose to improve the performance of unit operations within the Bayer process, in particular to enhance the settling of fine alumina trihydrate crystals.
In the typical Bayer process for the production of alumina trihydrate, bauxite ore is pulverized, slurried with caustic solution, and then digested at elevated temperatures and pressures. The caustic solution dissolves oxides of aluminum, forming an aqueous sodium aluminate solution. The caustic-insoluble constituents of bauxite ore are then separated from the aqueous phase containing the dissolved sodium aluminate. Solid alumina trihydrate product is precipitated out of the solution and collected as product.
As described at least in part, among other places, in U.S. Pat. No. 6,814,873, the Bayer process is constantly evolving and the specific techniques employed in industry for the various steps of the process not only vary from plant to plant, but also are often held as trade secrets. As a more detailed, but not comprehensive, example of a Bayer process, the pulverized bauxite ore may be fed to a slurry mixer where an aqueous slurry is prepared. The slurry makeup solution is typically spent liquor (described below) and added caustic solution. This bauxite ore slurry is then passed through a digester or a series of digesters where the available alumina is released from the ore as caustic-soluble sodium aluminate. The digested slurry is then cooled, for instance to about 220° F., employing a series of flash tanks wherein heat and condensate are recovered. The aluminate liquor leaving the flashing operation contains insoluble solids, which solids consist of the insoluble residue that remains after, or are precipitated during, digestion. The coarser solid particles may be removed from the aluminate liquor with a “sand trap”, cyclone or other means. The finer solid particles may be separated from the liquor first by settling and then by filtration, if necessary.
The clarified sodium aluminate liquor is then further cooled and seeded with alumina trihydrate crystals to induce precipitation of alumina in the form of alumina trihydrate, Al(OH) 3 . The alumina trihydrate particles or crystals are then classified into various size fractions and separated from the caustic liquor. The remaining liquid phase, the spent liquor, is returned to the initial digestion step and employed as a digestant after reconstitution with caustic.
Within the overall process one of the key steps is that of precipitation of the alumina trihydrate from the clarified sodium aluminate liquor. After the insoluble solids are removed to give the clarified sodium aluminate liquor, also referred to as “green liquor”, it is generally charged to a suitable precipitation tank, or series of precipitation tanks, and seeded with recirculated fine alumina trihydrate crystals. In the precipitation tank(s) it is cooled under agitation to induce the precipitation of alumina from solution as alumina trihydrate. The fine particle alumina trihydrate acts as seed crystals which provide nucleation sites and agglomerate together and grow as part of this precipitation process.
Alumina trihydrate crystal formation (the nucleation, agglomeration and growth of alumina trihydrate crystals), and the precipitation and collection thereof, are critical steps in the economic recovery of aluminum values by the Bayer process. Bayer process operators strive to optimize their crystal formation and precipitation methods so as to produce the greatest possible product yield from the Bayer process while producing crystals of a given particle size distribution. A relatively large particle size is beneficial to subsequent processing steps required to recover aluminum metal. Undersized alumina trihydrate crystals, or fines, generally are not used in the production of aluminum metal, but instead are recycled for use as fine particle alumina trihydrate crystal seed. As a consequence, the particle size of the precipitated trihydrate crystals determines whether the material is to be ultimately utilized as product (larger crystals) of as seed (smaller crystals). The classification and capture of the different sized trihydrate particles is therefore an important step in the Bayer process.
This separation or recovery of alumina trihydrate crystals as product in the Bayer process, or for use as precipitation seed, is generally achieved by settling, cyclones, filtration and/or a combination of these techniques. Coarse particles settle easily, but fine particles settle slowly. Typically, plants will use two or three steps of settling in order to classify the trihydrate particles into different size distributions corresponding to product and seed. In particular, in the final step of classification a settling vessel is often used to capture and settle the fine seed particles. Within the settling steps of the classification system, flocculants can be used to enhance particle capture and settling rate.
The overflow of the last classification stage is returned to the process as spent liquor. This spent liquor will go through heat exchangers and evaporation and eventually be used back in digestion. As a result, any trihydrate particles reporting to the overflow in this final settling stage will not be utilized within the process for either seed or product. Effectively such material is recirculated within the process, creating inefficiencies. Therefore, it is important to achieve the lowest possible concentration of solids in the overflow of the last stage of classification to maximize the efficiency of the process.
As described for example in U.S. Pat. No. 5,041,269, conventional technology employs the addition of synthetic water soluble polyacrylate flocculants and/or dextran flocculants to improve the settling characteristics of the alumina trihydrate particles in the classification process and reduce the amount of solids in the spent liquor. While various flocculants are often used in the trihydrate classification systems of Bayer plants, it is highly desirable to reduce as far as possible, the loss of solids with the spent liquor.
Thus there is clear need and utility for a method of improving the classification and flocculation of precipitated alumina trihydrate in the Bayer process. Such improvements would enhance the efficiency of the production of alumina from bauxite ore.
The art described in this section is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention, unless specifically designated as such. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 CFR §1.56(a) exists.
BRIEF SUMMARY OF THE INVENTION
At least one embodiment of the invention is directed towards a method for settling alumina trihydrate in the Bayer process. The process comprises adding to the system an effective amount of cross-linked dextran or cross-linked dihydroxypropyl cellulose. The cross-linking is the result of reacting the dextran/dihydroxypropyl cellulose or dextran/dihydroxypropyl cellulose-containing substance with a bifunctional cross-linking agent under appropriate reaction conditions. The use of such a cross-linked dextran or cross-linked dihydroxypropyl cellulose flocculants results in improved settling of alumina trihydrate when compared to the use of conventional flocculants employed in this process. At least one embodiment of the invention is directed towards a method for producing alumina comprising the addition of a composition containing one or more polysaccharides, one of which is cross-linked dextran or cross-linked dihydroxypropyl cellulose to liquor of a Bayer process fluid stream. The composition may be added to said liquor in a trihydrate classification circuit of said alumina production process. The composition may be added to said liquor at one or more locations in said process where solid-liquid separation occurs. The addition locations may facilitate inhibiting the rate of nucleation of one or more alumina trihydrate crystals in said process. The addition location may facilitate reducing the rate of scale formation in said process. The composition may improve the yield of alumina trihydrate sequestration.
DETAILED DESCRIPTION OF THE INVENTION
For purposes of this application the definition of these terms is as follows:
“Dextran” is an α-D-1,6 glucose-linked glucan with side chains 1-3 linked to the backbone units of the biopolymer.
“Dihydroxypropyl cellulose” is a cellulose derivative with the addition of 1,2-dihydroxypropyl ether group to the cellulose backbone.
“Liquor” or “Bayer liquor” is liquid medium that has run through a Bayer process in an industrial facility.
In the event that the above definitions or a description stated elsewhere in this application is inconsistent with a meaning (explicit or implicit) which is commonly used, in a dictionary, or stated in a source incorporated by reference into this application, the application and the claim terms in particular are understood to be construed according to the definition or description in this application, and not according to the common definition, dictionary definition, or the definition that was incorporated by reference. In light of the above, in the event that a term can only be understood if it is construed by a dictionary, if the term is defined by the Kirk - Othmer Encyclopedia of Chemical Technology, 5th Edition, (2005), (Published by Wiley, John & Sons, Inc.) this definition shall control how the term is to be defined in the claims.
In at least one embodiment, a process for extracting alumina trihydrate comprises the digestion of pretreated bauxite ore in an alkaline liquor to produce a slurry of red mud solids and aluminate in suspension in the alkaline liquor then decanting the red mud solids from the alkaline liquor suspension to produce the decanting liquor; the passing of said decanting liquor through security filtration to remove all solids, precipitation and production of a slurry containing alumina trihydrate solids which then are flocculated and settled with the addition of a cross-linked polysaccharide. Larger trihydrate particles are put through the calcination process to produce purified alumina while finer particles are re-used as seed for the precipitation process.
In at least one embodiment the preferred flocculant of the trihydrate solids in the process is a crosslinked polysaccharide and the preferred polysaccharides are dextran and dihydroxypropyl cellulose. The flocculant is added in the range of 0.1 to 100 ppm. The most preferred dose range for the flocculant is 0.3 to 20 ppm.
In at least one embodiment a cross-linked dextran or cross-linked dihydroxypropyl cellulose is produced by addition of dextran or dihydroxypropyl cellulose to an alkaline solution containing sodium hydroxide, potassium hydroxide, or other alkali metals or water soluble alkaline earth metal hydroxide, to provide a causticized polymer solution having a pH in the range of 11 to 14. The causticized polysaccharide is then reacted with an appropriate bifunctional cross-linking agent. Suitable cross-linking agents able to react with two or more hydroxyl groups include but are not limited to epichlorohydrin, dichloroglycerols, divinyl sulfone, bisepoxide, phosphorus oxychloride, trimetaphosphates, dicarboxylic acid anhydride, N,N′-methylenebisacrylamide; 2,4,6-trichloro-s-triazine and the like. The cross-linking with one of the above reagents results in the causticized polymer solution becoming a highly viscous solution or paste. When an optimum desired solution viscosity is reached, the reaction can be terminated via pH neutralization of the solution with an appropriate acidic solution examples of which are acetic acid, sulfuric acid, hydrochloric acid and the like.
As described at least in U.S. Pat. Nos. 6,726,845, 6,740,249, 3,085,853, 5,008,089, 5,041,269, 5,091,159, 5,106,599, 5,346,628 and 5,716,530 and Australian Patents 5310690 and 737191, dextran itself has previously been used in the Bayer Process.
However, by cross-linking the dextran or dihydroxypropyl cellulose chains (or for that matter, other suitable polysaccharides), superior and unexpected improvements are observed in the activity of cross-linked material when compared to conventional polysaccharides or the uncross-linked analog. Prior art uses of polysaccharides are impaired by the fact that increasing dosages of polysaccharides in Bayer liquor result in superior flocculation only up to a maximum dosage. After the maximum dosage has been reached, further addition of such polysaccharide material typically produces no further performance improvement. When the cross-linked polysaccharides are used and in particular when cross-linked dextran is used, superior performance (not possible at any dose rate using conventional polysaccharides) can be achieved. Surprisingly the maximum performance of cross-linked dextran is superior to the maximum performance using conventional dextran at any dose. Additionally, for cross-linked polysaccharides, the dose at which continued addition results in no further performance benefits is increased.
Furthermore, when the polysaccharide is cross-linked an unexpected 50% increase in effectiveness has been observed. For example, a composition comprising 5% cross-linked dextran will perform at least as well as a 10% composition of dextran, and in some cases better.
U.S. Pat. Nos. 5,049,612 and 4,339,331 teach that in mining applications such as sulfide ore flotation, it was found that the performance of starch, a traditional flotation depressant, can be improved after cross-linking. So while it is true that cross-linked polysaccharides have been used in mining applications such as in U.S. Pat. Nos. 5,049,612 and 4,339,331, it is quite unexpected that in Bayer process applications, the activity of dextran would be significantly improved after cross-linking. Furthermore, the ability of cross-linked polysaccharides to have up to or at least a 50% improvement in performance or to increase the maximum effective dosage of polysaccharides is unexpected and novel. In at least one embodiment the mass ratio of a general cross linking reagent/polysaccharide can be varied between, but is not limited to, about 0 to 0.2. Specifically, for epichlorohydrin as the cross linking reagent, the ratio can be varied between, but is not limited to, 0 to 0.1, most preferably 0.005 to 0.08. Appropriate cross-linking is achieved as measured by an increase in the solution viscosity of at least 10% above the original solution viscosity.
In at least one embodiment the composition is added to liquor in a trihydrate classification circuit of said alumina trihydrate production process. The composition can be added to said liquor at one or more locations in a Bayer process where solid-liquid separation occurs.
In at least one embodiment the composition can be added to said liquor at one or more locations in a Bayer process where it inhibits the rate of nucleation of one or more alumina hydrate crystals in said process.
In at least one embodiment the composition can be added to said liquor at one or more locations in a Bayer process where it reduces the rate of scale formation in said process.
In at least one embodiment the composition can be added to said liquor at one or more locations in a Bayer process where it facilitates red mud clarification in the process.
In at least one embodiment the composition can be added in combination with or according to any of the compositions and methods disclosed in commonly owned and at least partially co-invented co-pending patent application having an attorney docket number of 7987 and a title of “THE RECOVERY OF ALUMINA TRIHYDRATE DURING THE BAYER PROCESS USING SCLEROGLUCAN.”
EXAMPLES
The foregoing may be better understood by reference to the following examples, which are presented for purposes of illustration and are not intended to limit the scope of the invention.
Example 1
A series of cross-linked dextran products were produced using a conventional cross-linking process familiar to those skilled in the art where dextran (commercially available from Sigma-Aldrich) was added to a caustic solution and subsequently cross linked by reacting with epichlorohydrin. Within this method a variety of epichlorohydrin/dextran ratios varying from 0.030 to 0.055 were used to produce a range of materials with different levels of cross-linking, which were monitored through the increase of solution viscosity. These were denoted as products A-D. The performance of these cross-linked dextran products was compared to the performance of dextran in a series of settling tests using the following method.
A series of 200 mL samples of a Bayer process slurry were prepared each comprising 50 g/L aluminum trihydrate solids (DF225 aluminum trihydrate, commercially available from RJ Marshall Co, USA) and Bayer process liquor (with total caustic 233.6 g/l as Na 2 CO 3 ). The Bayer process liquor samples were each equilibrated at 60° C. in 250 ml Nalgene bottles for 1 hour. Then the aluminum trihydrate solids were added to the bottles and mixed for 30 seconds. Dextran or its cross-linked analogs were then added as appropriate to individual bottles containing the hot slurry and the bottles were mixed for 1 minute and then left to settle for 3 minutes. The unsettled solids from each bottle, (and hence an indication of flocculation performance) was measured by filtering a 60 ml aliquot of slurry taken from the top of the liquor after the 3 minute settling period. Each sub-sample was filtered through a pre-weighed No. 934 AH filter paper and washed with hot deionized water. The filter paper and contents were then dried at 100° C. and reweighed. Solids content of the 60 mL sub-sample were then calculated in g/L. From the results listed in Table 1, it is evident that, compared to the use of dextran, the flocculation performance was significantly improved for all cross-linked dextran products. This was evident across the whole range of cross-linking ratios.
TABLE 1
Settling tests of standard aluminum trihydrate with
addition of dextran and cross-linked dextrans
Dose
Unsettled
Product
(ppm)
solids (g/L)
Dextran
2.1
18.40
A
2.0
14.18
B
2.0
13.93
C
1.4
10.75
D
2.0
9.93
C
2.0
9.77
Example 2
The same flocculation test method as that detailed in example 1 was used in this example. However, the performance of the products at two separate dose rates was assessed in this test. Additionally, another cross-linked dextran product (from a reaction where a epichlorohydrin/dextran ratio of 0.0575 was used) was also assessed across the two dose rates. This product was denoted as product E. Results of are listed in Table 2. With only one exception, all cross-linked analogs outperformed dextran at both dose rates (from 1 to 2 ppm).
TABLE 2
Settling tests of standard aluminum trihydrate with
addition of dextran and cross-linked dextrans
Dose
Unsettled
Product
(ppm)
solids (g/L)
Dextran
1
16.73
A
1
15.92
B
1
15.82
D
1
15.80
C
1
14.33
E
1
14.28
Dextran
2
10.58
A
2
11.13
B
2
10.25
D
2
9.48
C
2
7.98
E
2
8.20
Example 3
The same flocculation test method as that detailed in examples 1 and 2 was used in this example. However, a series of cross-linked dextran products, denoted G-J were used in addition to product E. In the manufacture of these products a fixed ratio of epichlorohydrin to dextran was used but the reaction time was varied in the range from 4 hours to 16 hours. Results of are listed in Table 3. Those products with a shorter reaction time (denoted as products G, H and I), which have substantially less cross-linking of the dextran molecules, show no performance benefit versus dextran. However, those products where substantial cross-linking has taken place due to a longer reaction time (J and E), demonstrate superior flocculation performance versus dextran.
TABLE 3
Settling tests of standard aluminum trihydrate with
addition of dextran and cross-linked dextran samples.
Dose
Unsettled
Product
(ppm)
solids (g/L)
Dextran
2
8.35
G
2
8.48
H
2
8.42
I
2
8.22
J
2
7.72
E
2
5.77
Example 4
In this example, a series of one litre samples of fresh Bayer plant Secondary Overflow slurry (containing about 140 g/L solids) were collected from an operating plant in individual one litre bottles. These were then stored in an oven at 75° C. After equilibration at temperature, the samples were transferred to individual one litre cylinders and conventional settling tests using a gang plunger were conducted on the slurry samples. Treatments using dextran and cross-linked dextran (product E) were compared at a variety of doses as detailed in Table 4. After mixing of the flocculant, the slurry was allowed to settle for 4 minutes before removal of a 60 ml sub-sample from the top of the cylinder. Samples from each treated slurry were filtered using a 0.45 micron glass microfibre filter paper, washed with hot deionized water and then dried. The mass of solids collected in the samples were then determined and recorded as an indication of flocculation performance. Table 4 shows the results of each treatment as the unsettled solids (reported in g/L). Again it is apparent that compared to dextran, the addition of cross-linked dextran can significantly reduce the amount of unsettled solids that would normally report to the overflow of the settling vessel. At all doses, the cross-linked product reduces the amount of unsettled solids. This example also surprisingly shows that, while increasing doses of dextran beyond 1.6 ppm results in no further reduction in solids, increasing doses of the cross-linked product (E) results in a reduced amount of solids across the whole dose range. This result surprisingly indicates that while the maximum benefit of the dextran is achieved within this dose range, further improvements in flocculation across this entire dose range are achieved using the cross-linked product.
TABLE 4
Settling tests of seed secondary overflow with addition
of dextran and cross-linked dextran at different dosages
Dose
Unsettled
Product
(ppm)
solids (g/L)
Dextran
0.3
4.33
E
0.3
3.47
Dextran
0.5
3.50
E
0.5
2.24
Dextran
1
2.32
E
1
1.66
Dextran
1.6
1.92
E
1.6
1.40
Dextran
2
1.98
E
2
1.13
Example 5
Fresh Bayer plant Secondary Overflow slurry (containing approximately 67 g/L solids) was collected from an operating plant and placed into a series of one litre measuring cylinders. These were then equilibrated and stored in a waterbath at 65° C. A conventional settling test using a gang plunger was then conducted on the slurry samples. After mixing of the treatments, settling rates were determined by measuring the time taken for the solid/liquor interface to pass the 600 ml mark on each cylinder. Samples were allowed to settle for 4 minutes then a 50 ml sub-sample of slurry was taken from the top of each cylinder and the solids content determined as outlined in example 4. In this example, a cross-linked dextran (denoted as product Q) was used. It was produced from a reaction using an epichlorohydrin/dextran mass ratio of 0.02. Treatments using dextran and cross-linked dextran (product Q) were compared at a variety of doses as detailed in Table 5.
TABLE 5
Settling tests of seed secondary overflow with addition
of dextran and cross-linked dextran at different dosages
Dose
Settling rate
Unsettled
Product
(ppm)
(m/hr)
solids (g/L)
Dextran
2
4.5
0.96
Q
0.5
4.8
1.33
Dextran
4
5.3
0.77
Q
1
6.8
0.77
The data in table 5 indicates that even when cross-linked dextran was used at significantly lower dosages compared to dextran, superior settling rates and residual solids levels at or close to that observed with dextran treatment (at much higher dosage rates) were achieved.
Example 6
A similar method to that used in example 5 was also employed in this example. The slurry sample collected from the plant contained 67 g/L solids. In this example a series of products containing a mixture of dextran and cross-linked dextran were assessed. A product containing both dextran and cross-linked dextran together was formulated. The dextran/cross-linked dextran ratio of this product was approximately 10:1. The settling performance of this product (denoted Z) was assessed in a settling test and compared to the activity of dextran and cross-linked dextran (product Q) alone. Results are shown in Table 6.
TABLE 6
Settling tests of seed secondary overflow with
addition of dextran, cross-linked dextran (Q)
and dextran/cross-linked dextran combinations.
Dose
Settling Rate
Unsettled Solids
Product
(ppm)
(m/hr)
(g/L)
Dextran
5.0
4.42
0.58
Q
0.5
4.86
1.17
Z
5.5
5.28
0.49
A combination of dextran and cross-linked dextran together (product Z) improves both settling rate and overflow solids content when compared to the individual components when used alone.
Example 7
A similar method to that used in examples 5 and 6 was also employed in this example. The solids content of the slurry used was 84 g/L. Dextran at various doses was compared to a cross-linked dextran (product Q) applied at much lower doses. Results are shown in Table 7.
TABLE 7 Settling tests and overflow solids of seed secondary overflow with addition of dextran or cross-linked dextran. Dose Settling Rate Unsettled Solids Product (ppm) (m/hr) (g/L) Dextran 4 4.86 0.582 Dextran 3 4.42 0.815 Dextran 2 4.15 0.939 Q 1.40 6.23 0.706 Q 1.05 5.93 0.952 Q 0.70 5.65 1.155
Cross-linked dextran, when applied at low doses, shows faster settling rate and reduced overflow solids compared to dextran.
Example 8
A similar method to that used in examples 5, 6 and 7 was also employed in this example. The solids content of the slurry used was 67 g/L. Two products containing combinations of dextran and cross-linked dextran (denoted S and T) were compared to the use of cross-linked dextran (product Q). Results are shown in Table 8.
TABLE 8 Settling tests of seed secondary overflow with addition of dextran, cross-linked dextran (Q) and dextran/cross-linked dextran combinations. Settling Rate Unsettled Solids Product (m/hr) (g/L) Q 4.86 1.174 S 5.17 0.766 T 5.01 0.629
The addition of dextran to cross-linked dextran in products S and T improves performance in both settling rate and clarity.
Example 9
The same flocculation test method as that detailed in example 1 was used in this example. However, the products tested were dextran, dihydroxypropylcellulose (W) and its cross-linked analogs (X, Y). The results are listed in Table 9. From the results, it is evident that, compared to the use of dihydroxypropylcellulose, the flocculation performance was significantly improved after cross-linking. Furthermore, the cross-linked dihydroxypropyl cellulose outperformed dextran in to overflow solids reduction.
TABLE 9
Settling tests of standard aluminum trihydrate with
addition of dihydroxypropyl cellulose (W) and cross-
linked dihydroxypropyl cellulose (X, Y)
Dosage
Unsettled Solids
Product
(ppm)
(g/L)
Dextran
2
3.8
W
2
18.5
X
2
3.03
Y
2
2.05
While this invention may be embodied in many different forms, there are shown in the drawings and described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the background and principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific papers, and any other referenced materials mentioned anywhere herein are incorporated by reference in their entirety. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments described herein and incorporated herein.
The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
All ranges and parameters disclosed herein are understood to encompass any and all subranges subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, (e.g. 1 to 6.1), and ending with a maximum value of 10 or less, (e.g. 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range.
This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
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The invention provides methods and compositions for improving the production of alumina hydrate. The invention involves adding one or more polysaccharides to liquor or slurry in the fluid circuit of the production process. The one or more polysaccharides can be a cross-linked polysaccharide (such as cross-linked dextran or cross-linked dihydroxypropyl cellulose). The various polysaccharides can impart a number of advantages including at least some of: greater flocculation effectiveness, increasing the maximum effective dosage, faster settling rate. The production process can be a Bayer process.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 60/433,283 filed on Dec. 16, 2002 and U.S. patent application Ser. No. 10/167,027 filed on Jun. 11, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a foot bath. More particularly, the present invention relates to a portable foot bath with a reservoir having a number of adjustable jets on a floor of the reservoir.
[0004] 2. Description of the Related Art
[0005] Foot therapy, Jacuzzi, and bath devices are known in the art. A number of such devices are capable of massaging the feet with heat, vibration, brushes, scrubbing devices or resilient members disposed on a bottom of a reservoir.
[0006] The prior art foot therapy devices may also provide a variety of massage sensations. These massage sensations include passing air bubbles across a surface of a user's feet in the foot therapy device, either alone or in combination with heat sensations, vibration sensations, and scrubbing sensations.
[0007] Generally, an objective in the prior art foot therapy devices is that the user initially places his or her feet in a basin or a reservoir of the foot therapy device. Thereafter, the user activates the foot therapy device to actuate the heat, the vibrations, and/or the scrubbing devices to provide soothing and relaxing therapy to the feet by increasing blood circulation in the feet. Depending upon the temperature of the liquid placed in the foot therapy device and the contents of the liquid in the foot therapy device, the foot therapy device may soften the skin, and relax muscles and joints.
[0008] However, the prior art foot therapy devices are limited in their operation. The prior art foot therapy devices pay little, if any, attention to the fluid flow patterns in the reservoir. This continuous and random movement or chaotic shaking is distracting to the user. This chaotic shaking is caused predominately by the air bubbles and the vibration.
[0009] A vibrating device will cause the fluid disposed in the reservoir to flow in a turbulent manner. This turbulent flow pattern is distracting and aesthetically displeasing to the user, especially in the instance where the user initially places his or her feet in the reservoir.
[0010] The turbulent flow pattern produced by the prior art may further cause the fluid in the reservoir to splash out of the reservoir and on to the floor. These turbulent flow patterns are generally uninviting and undesirable as they are distracting to the user. Accordingly, there is a need for a foot bath that eliminates one or more of the aforementioned drawbacks and deficiencies of the prior art.
SUMMARY OF THE INVENTION
[0011] It is an object of the present invention to provide a foot bath that creates a first whirling flow pattern and a second whirling flow pattern from a liquid in a reservoir.
[0012] It is another object of the present invention to provide a foot bath that creates a relaxing flow pattern that is aesthetically pleasing to a user and relaxes the user.
[0013] It is still another object of the present invention to provide a foot bath that does not shake chaotically and does not create any turbulent fluid flow pattern.
[0014] It is yet another object of the present invention to provide a foot bath with a reservoir that creates a laminar fluid flow in a predetermined whirling flow pattern in the reservoir.
[0015] It is still yet another object of the present invention to provide a foot bath that has a first outlet and a second outlet in a floor of the reservoir that communicates with a pump in the foot bath.
[0016] It is a further object of the present invention to provide a foot bath that has a number of adjustable jets disposed through the floor that communicate with the pump.
[0017] It is still a further object of the present invention to provide a foot bath that has an adjustable jet that sprays fluid in a horizontal manner, that can be adjusted to spray upwardly from the horizontal manner, and that can be further adjusted to spray downwardly from the horizontal manner.
[0018] These and other objects and advantages of the present invention are achieved by a portable foot bath of the present invention. The portable foot bath has a reservoir for holding a volume of liquid. The reservoir has a diameter, a wall, and a floor. The foot bath has a jet disposed on the floor with the jet being connected to a pump. The foot bath has a first outlet in a first location of the floor and a second outlet in a second location of the floor. The second location is in a different location than the first location. The jet circulates the liquid in the reservoir. The liquid escapes through the first and second outlets to create a first and second whirling flow patterns from the liquid in the reservoir.
DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a perspective view of a preferred embodiment of the foot bath according to the present invention;
[0020] [0020]FIG. 2 is a perspective view of the foot bath of FIG. 1 with a lid;
[0021] [0021]FIG. 3 is a an alternative embodiment of the foot bath of FIG. 2;
[0022] [0022]FIG. 4 is an enlarged top view of a first footrest and a second footrest of the foot bath of FIG. 3;
[0023] [0023]FIG. 5 is a perspective view of an interior portion of the foot bath of FIG. 4 showing an aeration portion of the foot bath;
[0024] [0024]FIG. 6 is an enlarged top perspective view of the aeration device of FIG. 5;
[0025] [0025]FIG. 7 is a perspective view of a portion of a reservoir of the foot bath of FIG. 2 showing a number of adjustable jets;
[0026] [0026]FIG. 8 is a perspective view of an adjustable jet of FIG. 7;
[0027] [0027]FIG. 9 is an enlarged perspective view of a section of the interior of the foot bath of FIG. 8 where the adjustable jet is connected to a tube;
[0028] [0028]FIG. 10 is another perspective view of the interior of the foot bath of FIG. 9;
[0029] [0029]FIG. 11 is another top view of the foot bath of FIG. 2 showing a first drain and a second drain;
[0030] [0030]FIG. 12 is an enlarged top perspective view of the second drain of FIG. 11;
[0031] [0031]FIG. 13 is another interior view of the foot bath of FIG. 2;
[0032] [0032]FIG. 14 is a perspective view of the foot bath of FIG. 1 showing a first whirling flow pattern and a second whirling flow pattern;
[0033] [0033]FIG. 15 is a top view of the foot bath of FIG. 2;
[0034] [0034]FIG. 16 is still another interior view of the foot bath of FIG. 15;
[0035] [0035]FIG. 17 is an enlarged perspective view of a heater of FIG. 16; and
[0036] [0036]FIG. 18 is a bottom view of the foot bath of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Referring to FIG. 1, there is provided a foot bath of the present invention generally represented by reference numeral 10 . The foot bath 10 preferably is supported on a floor or a similar flat surface for treating, massaging and softening a user's feet. The foot bath 10 preferably imparts a relaxing massage to the user's feet by circulating water in a first and second whirling flow patterns around each foot in the foot bath. This overcomes deficiencies of the prior art foot baths with chaotic, violent, agitated and turbulent flow.
[0038] The foot bath 10 has a housing 12 that forms a reservoir 14 . Preferably, the housing 12 is made from a resilient and durable material such as a thermoplastic, a thermoset, a metal, a composite, or any combinations thereof.
[0039] The reservoir 14 is preferably a receptacle or chamber for storing a fluid, such as water or a water based mixture that has soap or skin softeners, disposed therein. Preferably, the reservoir 14 is generally circular in shape and has a suitable diameter 16 so that a pair of feet can be easily and comfortably positioned in the reservoir. Further, the housing 12 has a number of legs 18 . Each leg 18 is a disk shaped member. The legs 18 support the foot bath 10 on the floor or the ground for operation thereon.
[0040] Referring to FIG. 2, the reservoir 14 of the housing 12 has an inner wall 20 and a bottom floor 22 . The reservoir 14 retains the water. The inner wall 20 extends substantially perpendicular from a bottom floor 22 . The inner wall 20 has a height such that a volume of water can be disposed in the reservoir 14 to preferably substantially entirely cover the user's feet, and more preferably up to a user's ankles to maximize foot therapy.
[0041] Referring to FIG. 3, the reservoir 14 has a first foot rest 24 and a second foot rest 26 . Both the first foot rest 24 and the second foot rest 26 are positioned on the bottom floor 22 of the reservoir 14 . The first foot rest 24 and the second foot rest 26 are both preferably a support structure in which the user's feet can comfortably rest. Preferably, the first foot rest 24 and the second foot rest 26 are a number of raised grooves disposed on or in the bottom floor 22 of the foot bath 10 .
[0042] Alternatively, the first foot rest 24 and the second foot rest 26 could also be foot shaped indentations disposed above, on, or in the bottom floor 22 to comfortably rest the user's feet while engaging in the desired foot therapy. One skilled in the art should appreciate that the first foot rest 24 and the second foot rest 26 are comfortable and designed so that the user's feet may be disposed thereon for an extended period of time.
[0043] Additionally, the first foot rest 24 and the second foot rest 26 preferably both provide a tactile feedback as to a correct orientation of the user's respective left and right foot in the reservoir 14 of the foot bath 10 . One skilled in the art should appreciate that the first foot rest 24 and the second foot rest 26 can have lines, grooves, protrusions or demarcations. Alternatively, a pad can be connected on the bottom floor 22 of the reservoir 14 that is comfortable when the user's feet is disposed thereon for an extended period of time.
[0044] Referring to FIG. 4, there is shown a close up or exploded view of the first foot rest 24 and the second foot rest 26 of the foot bath 10 . The first foot rest 24 has a first aeration tube 28 disposed thereon, and the second foot rest 26 has a second aeration tube 30 disposed thereon. Each of the first aeration tube 28 and the second aeration tube 30 have a number of apertures 32 disposed therein. One skilled in the art should appreciate that each of the first aeration tube 28 and the second aeration tube 30 may have any shape known in the art and have any number of apertures thereon.
[0045] Referring to FIG. 5, beneath the bottom floor 22 , the first aeration tube 28 , and the second aeration tube 30 , there is shown a number of internal components of the foot bath 10 of the present invention. Preferably, the first aeration tube 28 and the second aeration tube 30 are both connected through the bottom floor 22 to an aeration device 70 in the housing 12 in the interior of the foot bath 10 .
[0046] The aeration device 70 is preferably a suitable air pump. However, the aeration device 70 may be any suitable device that forces fresh air over time through the number of apertures 32 to massage and contact the user's feet. Referring to FIG. 6, the aeration device 70 is preferably connected to the first aeration tube 28 and the second aeration tube 30 by suitable tubing 71 . The aeration device 70 releases an amount of fresh air through the tubing 71 and to the first aeration tube 28 and the second aeration tube 30 .
[0047] Referring to FIG. 7, the first aeration tube 28 and the second aeration tube 30 preferably emit bubbling air through the water in the reservoir 14 under the soles of the user for a period of time. In this manner, the first aeration tube 28 and the second aeration tube 30 massage with air the soles of the user's feet that are disposed on the first foot rest 24 and the second foot rest 26 .
[0048] The foot bath 10 has a number of adjustable jets 34 . Preferably, each of the number of adjustable jets 34 is substantially “L” shaped and is disposed through the bottom floor 22 as shown in a watertight manner. Alternatively, the adjustable jets 34 may be disposed in any suitable location in the housing 12 to create the first and the second whirling flow pattern. For example, the adjustable jets 34 may be alternatively disposed on the inner wall 20 or in any other suitable location on the bottom floor 22 . Each adjustable jet 34 preferably has a small diameter opening or a nozzle 36 . In this preferred embodiment, each adjustable jet 34 is at an edge of the foot bath 10 or at a location near an intersection on the bottom floor 22 and the inner wall 20 .
[0049] As is shown in FIG. 8, each adjustable jet 34 may have one or more nozzles 36 . The one or more nozzles 36 provide for directing water in one or more directions from each adjustable jet 34 . Each adjustable jet 34 forces a high-velocity water stream under pressure out of the nozzle 36 for circulating the water in the whirling flow pattern in the reservoir 14 in a counterclockwise or clockwise direction.
[0050] Each adjustable jet 34 may have a tab 37 . The tab 37 is preferably an orthogonal shaped projection, flap, or short strip connected to the adjustable jet 34 . Preferably, the tab 37 is connected to the top of the adjustable jet 34 . However, one skilled in the art should appreciate that the tab 37 may be connected in any location on the adjustable jet 34 for manipulating the adjustable jet by an application of a force by the user. The tab 37 preferably facilitates rotating the adjustable jet 34 in one or more directions to allow the user to selectively change direction of the water escaping the nozzle 36 .
[0051] Referring to FIGS. 9 and 10, each adjustable jet 34 preferably is connected to a pump 72 in the housing 12 by a suitable tube 74 .
[0052] Referring to FIG. 11, the adjustable jets 34 are preferably in a radial array around an edge of the reservoir 14 of foot bath 10 . Also, preferably, all of the adjustable jets 34 point in a clockwise or a counterclockwise direction. This arrangement preferably ensures that the first and the second whirling flow patterns are created. However, one skilled in the art should appreciate that the number of adjustable jets 34 may be disposed in any manner or orientation to ensure that the first and second whirling fluid flow patterns are created.
[0053] Preferably, the foot bath 10 has four adjustable jets 34 as shown. However, one skilled in the art should appreciate that the foot bath 10 may have any number of adjustable jets 34 to ensure that the first and second whirling flow patterns are created. Also each of the adjustable jets 34 may have any shape known in the art with any sized nozzle 36 for spraying water in the reservoir 14 . Preferably, each adjustable jet 34 with the nozzle 36 sprays the water in a substantially horizontal manner parallel with the bottom floor 22 .
[0054] However, the user may selectively adjust the direction of the spray of each adjustable jet 34 , if the user desires a localized massaging action on, for example, a rear or lateral side of the treated foot. In a first aspect or embodiment of the present invention, the direction of each adjustable jet 34 may be changed either upwardly or downwardly relative to the bottom floor 22 by physically pushing or pulling each adjustable jet by the tab 37 upward or downward a desired amount. The direction may be further adjusted to spray water upward relative to the substantially horizontal manner or adjusted downward relative to the substantially horizontal manner, by pushing the adjustable jet 34 upward by the tab 37 or pulling the adjustable jet downward by the tab. Each adjustable jet 34 may further be selectively rotated from a clockwise position to a counterclockwise position to change a position of the spray pattern. The user may selectively twist each adjustable jet 34 in a counterclockwise or clockwise manner to further change a position of the spray pattern of the adjustable jet.
[0055] The foot bath 10 has a first drain 38 and a second drain 40 . The first drain 38 is adjacent to the second drain 40 . Preferably, the first drain 38 is disposed a distance away from the second drain 40 . Preferably, the first drain 38 is about 6.25 inches away from the second drain 40 . The first drain 38 and the second drain 40 are preferably an outlet of the reservoir 14 disposed on the bottom floor 22 .
[0056] Referring to FIG. 12, each of the first and the second drains 38 , 40 have a suitable grate 42 connected thereto. The grate 42 is connected over each of the respective first drain 38 and second drain 40 . The grate 42 is preferably a convex shaped structure and extends outward an amount opposite from the bottom floor 22 .
[0057] The grate 42 has framework of parallel or latticed bars for blocking an opening of each of the first and the second drains 38 , 40 . Preferably, the grate 42 is positioned in a comfortable location of both the first foot rest portion 24 and the second foot rest portion 26 . Preferably, the grate 42 is located in the same location where an arch of the user's foot rests when on the bottom floor 22 .
[0058] Referring to FIG. 13, each of the first drain 38 and the second drain 40 are disposed on an opposite side of the bottom floor 22 being generally represented by reference numeral 71 . The first drain 38 and the second drain 40 are connected to the pump 72 under the reservoir 14 . The pump 72 is preferably any mechanical device known in the art that moves the water from the first drain 38 and the second drain 40 to each adjustable jet 34 shown in FIG. 11, by pressure or suction through the tube 74 . The pump 72 is preferably connected to each adjustable jet 34 underneath the opposite side 71 of the bottom floor 22 in a watertight manner. Thus, the water exiting the first drain 38 and the second drain 40 is pulled toward the pump 72 and circulated back to each adjustable jet 34 to introduce and spray the water in the reservoir 14 in the first and second whirling flow patterns.
[0059] In one aspect or embodiment of the present invention shown in FIG. 14, the foot bath 10 has the adjustable jets 34 arranged to surround the first drain 38 and the second drain 40 and thus to circulate the water around each of the first drain and second drain. Most preferably, the water through the first drain 38 and the second drain 40 create the first whirling flow pattern and the second whirling flow pattern, respectively from the water in the reservoir 14 in a direction of reference arrows 102 , 104 , respectively.
[0060] Preferably, the first whirling flow pattern and the second whirling flow pattern are both a spiral motion of water in the reservoir 14 . Preferably, the first drain 38 and the second drain 40 are at a substantially centermost portion of each of the spiral motions of the first whirling flow pattern and the second whirling flow pattern. Preferably, the first drain 38 and the second drain 40 draws all of the water near the center of the respective first and second whirling flow patterns to the pump 72 in the housing 12 underneath the bottom floor 22 shown in FIG. 13. Thus, the first and the second whirling flow patterns are created in the reservoir 14 for an aesthetically pleasing and relaxing foot massage. This ordered pattern is superior to the prior art chaotic shaking foot bath and that is distracting and aesthetically displeasing to the user.
[0061] Referring to FIG. 15, the foot bath 10 has a controller or control button 44 . The control button 44 is on a raised structure 46 of the housing 12 . The control button 44 may alternatively be in any suitable location on the housing 12 for easy and comfortable access. Preferably, the control button 44 may be a waterproof button, a knob, an analog dial, a switch, or any number of buttons. The control button 44 may alternatively be digital controller or be any other controller with any configuration known in the art.
[0062] The control button 44 is adjustable, to various settings including, for example, “vibration on”, “vibration off”, “heat on”, “heat off”, “aeration on”, “aeration off”, “jets on” and “jets off”, or any combinations thereof, to activate or deactivate one or more features of the foot bath 10 .
[0063] Alternatively, the foot bath 10 may have a receiver 77 . The receiver 77 is preferably an infrared receiver or a radio frequency receiver for remote operation. Preferably, the receiver 77 may be disposed on a portion of the raised structure 46 of the foot bath 10 for communication with a suitable complementary remote control unit. In an alternative embodiment of the present invention, the remote control unit may be optionally tethered to the housing 12 to prevent misplacing the remote control unit.
[0064] Referring to FIG. 16, the foot bath 10 has a vibration device 76 in the housing 12 . The vibration device 76 preferably imparts a shaking or a limited reciprocating motion to shake the housing 12 and massage the user's feet. Preferably, the vibration device 76 is secured under the bottom floor 22 shown in FIG. 15 in the housing 12 under the reservoir 14 . Preferably, the vibration device 76 shakes the first foot rest portion 24 and the second foot rest portion 26 shown in FIG. 15.
[0065] The foot bath 10 has a heater 78 . The heater 78 is preferably a high electrical resistance heater wire that is connected to a power supply (not shown). Preferably, the power supply is external from the foot bath 10 and the foot bath is for use with a 120 volt circuit. Once actuated, the heater wire 78 preferably receives an electrical current from the power supply. The electrical current traversing through the heater wire 78 causes the heater wire to emit heat that preferably heats a portion of the user's feet or soles and the water in the reservoir 14 . In one embodiment of the present invention shown in FIG. 17, the heater wire 78 is in a serpentine fashion in a channel 80 formed underneath the bottom floor 22 of the reservoir 14 , preferably under the first foot rest portion 24 and the second foot rest portion 26 .
[0066] Referring again to FIG. 1, the foot bath 10 also has a first pad 48 and a second pad 50 . The first pad 48 and second pad 50 are both preferably a thin, cushion-like mass of soft material that is connected to the inner wall 20 or alternatively connected to a lid that is hinged to the reservoir 14 shown in FIG. 3. Preferably, the first pad 48 and the second pad 50 are removably connected to a lid being shown in FIG. 15. Less preferably, the first pad 48 and the second pad 50 may be directly connected to the bottom floor 22 or in any suitable location on the housing 12 . The first pad 48 and the second pad 50 are disposed above the first and the second foot rest portions 24 , 26 . Preferably, the first and the second pads 48 , 50 may be made from an absorbent material. In this manner, the first pad and the second pad 48 , 50 dry the user's feet upon completion of the foot therapy when the user desires to exit the reservoir 14 . Alternatively, the first pad 48 and the second pad 50 may be made from a gel to impart comfort or alternatively may be made from a dried loofa. The first pad 48 and the second pad 50 are used as a washing sponge to remove dead skin from the user's soles during foot therapy.
[0067] The foot bath also has a massaging attachment 52 also shown in FIG. 1. The massaging attachment 52 is a circular structure that has a number of convex protrusions 54 thereon. The massaging attachment 52 , when actuated, preferably vibrates and rotates to massage the foot that is on the massaging attachment. In an embodiment of the present invention, depressing the massaging attachment, such as by a user's foot an amount preferably actuates the massaging attachment from an “on” to an “off” position or from “off” to an “on” position. This actuation of the massaging attachment 52 preferably vibrates the massaging attachment and also causes the massaging attachment to rotate for added foot therapy.
[0068] Referring to FIG. 18, the foot bath 10 preferably has four legs 18 , a power cord 81 for linking the foot bath 10 to the power supply for household use and a number of vents 82 . The number of vents 82 are arranged in a circular configuration and preferably draw an amount of fresh air therethrough for the aeration device 70 and to cool the pump 72 , vibration device 76 and other components of the foot bath 10 .
[0069] It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances.
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A portable foot bath has a reservoir for holding a volume of liquid. The reservoir has a floor. The foot bath also has a jet connected to a pump. A first outlet is in a first location of the floor and a second outlet is in a second location of the floor that is a location different than the first location. The jet circulates the liquid in the reservoir. The liquid goes through the first outlet and the second outlet to create a first whirling flow pattern and a second whirling flow pattern, respectively, from the liquid in the reservoir.
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BACKGROUND OF THE INVENTION
This invention relates to erosion control systems, and more particularly to an erosion control system which utilizes a plurality of hexagonal blocks having tongue and cavity coupling means to form an entire revetment comprised of hand-placed blocks and/or preassembled machine-placed interlocking hexangular block mats.
The erosion of natural and artificial channels, beaches, and other points where water interfaces with soil is a frequently encountered and much studied problem. Erosion can be the result of abrasion, which is the removal of material from the surface of a bank. The primary cause of abrasion is the movement of water along the soil/water interface, with contributing factors being high velocities, currents, waves, long-eddies and boat wash.
Various revetment systems have been used in attempts at preventing, or at least slowing, erosion. Randomly sized concrete chunks, or "riprap", have been placed along riverbanks and beaches in attempts to slow erosion. Too often, though, the chunks would be too large and some erosion would still occur. Similarly, attempts at paving have been futile due to the destructive effects of hydrostatic pore pressure.
Recently, revetment constructions utilizing interconnected blocks have become known. These constructions typically involve placing blocks of various shapes into a mat which in turn, is placed along the riverbank or beach. These mats make intimate contact with the underlying soil during settlement and prevent realignment of the slope by wave and current action. However, because such constructions have ignored one or more basic considerations, there has yet to exist a truly effective means of preventing hydrodynamic failures due to waves and currents.
One overlooked consideration involves the "uplifting"of entire revetments due to hydrostatic pore pressure. When water passes between the bottom of a revetment, or an individual block, and the earth, hydraulic action takes place. This, for example, results when waves of passing vessels and natural variable frequency and wave heights cause turbulence, thereby affecting water pressures under the revetment and in the subsoil. When the uplift pressure forces become greater than the sum of the weight of the block and its friction forces, a loss of stability occurs, and one or more blocks can be lifted from the revetment.
A second overlooked consideration is that the interconnected blocks must be permitted to shift within reasonable bounds within the mat so as to avoid any individual block taking the entire destructive force outlined above, and yet be restrained so as not to become dislodged. If firmly restricted, the interconnecting members of the block are apt to break off or sheer when the blocks move during hydraulic action, which in turn can result in the dislocation of the block and the eventual loss of an entire revetment. This is especially important when concrete, which is low in tensile strength, is used to produce the blocks.
Another overlooked consideration relates to the means used to interlock the blocks. Reinforcing or connecting rods and cables made of material subject to corrosion, such as steel, are traditionally used because unlike plastic, such materials best withstand attempted vandalism and do not break down upon exposure to sunlight. However, corrosion of such cables, when surrounded in concrete, causes the concrete to expand, which in turn results in spalling. Once spalling of the concrete takes place, the blocks are apt to crack or disintegrate and the entire revetment can be lost. Attempts at replacing such cables using blocks having interconnecting members have been made, but all have failed. Such interconnections have involved either solely horizontal locking members or have failed to allow the movement of members outlined above, or both.
Another important, yet unmet, consideration is cost effectiveness. Any efficient erosion control system must have low production and application costs. To keep costs low, the blocks must be of such design that they can be quickly assembled into a mat at a desired location in a systematic fashion without auxiliary components and by relatively unskilled labor.
There exists a need, therefore, for a block-formed revetment mat which is sufficiently stable so that no part can be displaced, sufficiently flexible so that the mat can bend to a limited extent without losing mutual connection between the blocks, sufficiently durable so as not to break apart or disintegrate, and economical in that it can be manufactured and applied quickly and at low cost.
SUMMARY
The above considerations are embodied in the present invention, which is directed to a hand-placed block-formed revetment or a mat for controlling soil erosion.
Each block has, as its main body, a hexagonally shaped grid and connecting means extending from the grid. Each sidewall of the grid is comprised of two vertical planar faces; a lower vertical face and an upper vertical face which slopes inwardly from the lower face to the top portion of the grid. Each sidewall has, on its lower vertical face, either a tongue or a cavity capable of coupling with such tongue on its lower vertical face. The shape of each tongue and cavity is such as to allow the tongue some movement within the cavity while preventing total horizontal or vertical dislocation. This encourages a small amount of controlled movement among the blocks and prevents breaking off of tongues during such movement. The bottom of each tongue is co-planar with the bottom of the grid to reduce space between the block and the subsoil, thereby reducing hydraulic lifting action. When horizontal or vertical movement occurs no single vertical face or tongue and cavity takes the full impact. Rather, the impact is distributed to all vertical walls and tongues.
According to one embodiment of the invention, three types of blocks are used, each having a hexagonal grid. An inner edge block type has a tongue on each of two adjacent lower vertical grid faces, and a cavity on each remaining vertical grid face. An outer edge block type has a cavity on each of two adjacent lower faces, and a tongue on each of the four remaining faces. An interior block type has a tongue on each of three adjacent lower faces, and a cavity on each of the remaining three adjacent lower faces. Optionally, a fourth opened block having a pair of adjacent open grooves in place of cavities may be used as end blocks. These end blocks enable a cable to pass through a mat without exposure when double cabled mats, as described more fully below, are used.
Each block may also have a plurality of holes extending from the top surface through the block to bottom of the grid. These holes aid in reducing hydrostatic pressure, create a high flow resistance, and allow vegetation to grow through the blocks so as to further stabilize the mat comprised of a plurality of the blocks. Furthermore, the holes produce eddy currents as the water traverses over the block, and thereby increase flow resistance.
Each block may have a through tunnel at a point approximately one inch from its bottom and traveling through at least one tongue and ending at a cavity. The uniform location of the tunnel allows grids of different heights, and hence, different weights, to be interconnected as needed. Various types of steel cables, rods, or high tensile plastic or other non-corrodable material may be passed through the tunnels of interconnected blocks. This allows a mat to be pre-assembled on land (which is economically more efficient than on-site assembly in water) and placed as a unit into final position in and along the water. The parallel location of the interconnections results in a mat with a catenary curve conducive to lifting. Without such a catenary curve, the blocks would crack upon being lifted. The cable or rods may remain in the positioned mat to provide greater stability if desired. Because each cable travels through the interconnected tongues and cavities, it is not exposed as it passes between blocks. This prevents vandalism and disintegration of plastic cables due to sunlight. Also, since the blocks are mechanically interconnected, fewer cables are needed as compared to mats traditionally used.
The assembly of the mat is accomplished by placement of the cavity of one block over a tongue of another. Additional couplings are made until a mat of juxtaposed blocks is formed. If assembly is to be done without cables and at the point of final position, such as within the water, only the interior type blocks need be used. If assembly is off-site, a row of inner edge blocks is connected to one edge of the mat so that a cavity appears on each exposed vertical wall of an inner mat edge, and a row of outer edge blocks is connected at the opposite edge of the mat so that a tongue appears on each exposed vertical wall of an outer mat edge. Upon placing the mats into final position, the tongued outer edge of a first mat can be interconnected with the cavitied inner edge of a second mat. Additional mats can be similarly connected to produce a revetment of any desired length. Likewise, an upper mat edge having a series of exposed cavities is formed at one end of the mat, and a lower mat edge having a series of exposed connecting tongues is formed at the opposite end. The tongued lower mat edge of a first mat can be interconnected with the cavitied upper edge of a second mat to produce a revetment of any desired width.
The invention, therefore, is useful in preventing washing away of a shoreline, as well as in a desert, along a highway, or other instances where erosion is a problem.
It is, therefore, an object of this invention to provide a block which will couple with other similar blocks without separate or auxiliary interconnecting means to form a revetment capable of controlling erosion of soil.
It is a further object of this invention to provide a block which, when coupled with other blocks, allows a limited amount of movement of both the blocks themselves and their connecting tongues.
It is a still further object of this invention to provide a block which, when coupled with other blocks, forms a mat which allows minimum space between its bottom surface and the subsoil.
It is another object of this invention to provide a block and revetment mat which reduces the effects of hydrodynamic pressure.
It is yet another object of this invention to provide a block and revetment mat through which vegetation can grow.
It is still another object of this invention to provide a block and revetment mat which allows a cable or rod or tubing to be placed through hand placed blocks to provide increased resistance to hydraulic uplift.
It is yet a further object of this invention to provide a block which, when coupled with other blocks, eliminates the dislocation of connecting means by vertical or horizontal force.
It is still another object of this invention to provide a block which, when coupled with other blocks, has a catenary curve when lifted.
It is still another object of this invention to provide a block which, when coupled with other blocks, minimizes exposure of any connecting cable passing between the blocks.
It is still another object of this invention to provide a block of uniform design which can be assembled into a mat quickly and by minimally skilled labor.
It is yet still another object of this invention to provide a revetment mat capable of being preassembled and easily connected to a second preassembled mat to form an assembly of any length or width.
It is also a further object of this invention to provide a revetment mat which is sufficiently flexible so as to accommodate the contours of the site upon which it is installed.
These and other objects and advantages will appear from the following description with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view of a block according to the present invention.
FIG. 2 is a bottom view of a block according to the present invention.
FIG. 3 is a perspective view of a tongued-wall portion of a block according to the present invention.
FIG. 4 is a bottom perspective view of a block according to the present invention.
FIG. 5 is a bottom view of an interior block according to the present invention.
FIG. 6 is a bottom view of an inner edge block according to the present invention.
FIG. 6a is a bottom view of an opened block according to the present invention.
FIG. 7 is a bottom view of an outer edge block according to the present invention.
FIG. 8 illustrates a block being held in place by adjacent blocks.
FIG. 9 is an exploded view of a revetment mat according to the present invention.
FIG. 10 is an exploded view of a revetment comprised of three revetment mats according to the present invention.
FIG. 11 is a cross-sectional view of a revetment according to the present invention having varying sized blocks positioned along a shoreline.
FIG. 12 is a cross-sectional view of interlocking blocks according to invention.
FIG. 13 is a bottom perspective view of interlocking blocks according to the present invention.
FIG. 14 is a cross-sectional view if a revetment positioned along a shoreline.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the invention is now described with reference to the drawings, in which like numbers represent like parts throughout the views.
FIGS. 1 and 2 show a block 2, preferably made of concrete, used in the present invention. Each block 2 is comprised of a polygonal, and preferably hexagonal, grid member 4 and connecting means. The grid 4 has a top surface 6, a bottom a bottom surface 8, and six side surfaces 10 and 11, the side surfaces being either tongue side surfaces 10 or cavity side surfaces 11. The polygonal shape enables the block to resist hydrostatic forces in all directions, as discussed more fully below. Each grid 4 may also have a plurality of holes 50 extending from the top surface 6, through the grid 4 to the bottom surface 8. The holes 50 reduce hydrostatic pressure and permit vegetation to grow through the grid 4. These holes 50 may be square or circular in shape, the circular type being easier to produce. In addition, the diameter or number of the holes may be varied to account for weather conditions. For example, in colder regions, where a more solid block 2 is required, one may decrease the number of holes 50 or decrease the diameter of each hole 50, and thereby increase the strength of the block 2. Also, a solid block 2 may be used in extremely harsh environments. This will reduce the risk of the impact damage commonly caused by ice flows solid blocks 2 are also useful in areas where the subsoil is clay.
Referring to FIG. 1, a tongue side surface 10 has an upper side surface 12 and a lower side surface 14. The upper side surface 12 extends upward from a horizontal line 16 approximately midway vertically between the bottom surface 8 and the top surface 6 of the grid 4, to the top surface 6. The upper side surface 12 slopes inwardly from the vertical midway line 16 to the top surface 6. The lower side surface 14 extends from the midway line 16 to the bottom surface 8 of the grid 4 and is more vertical than the upper side surface 12.
Located on the lower side surface 14 of each tongue side surface, is a connecting tongue 18, shown in detail in FIG. 3. The tongue 18 is centered on the face 14 of the tongue side surface 10 and extends vertically from the bottom surface 8 of the grid 4 to approximately the vertical midway line 16. The tongue 18 has five exposed surfaces; a flat bottom tongue surface 22, a top tongue surface 24, a front tongue surface 26, and a pair of parallel side tongue surfaces 28 a and b. The top tongue surface 24 slopes downwardly from the front tongue surface 26 to the lower side surface 14 of the grid 4. The front tongue surface 26 slopes inwardly toward the top tongue surface 24. A first tongue edge 30 connecting the top tongue surface 24 and the front tongue surface 2 is rounded, as are a pair of second tongue edges 32 a and b connecting the top tongue surface 24 and each of the side tongue surfaces 28 a and b. A pair of third tongue edges 34 a and b connecting the front tongue surface 26 and the side tongue surfaces 28 a and b are similarly rounded. The line of connection 31 between the top tongue surface 24 and the block upper side surface 12 is the nature of an annular fillet. Furthermore, the connecting edge 32 where the top tongue surface 24 and the side tongue surfaces 28 a, b meet the grid are in the nature of an annular fillet. Also, each corner 33 where block side surfaces 14 meet tongue side surfaces 28 a, b is rounded, as is the connection along vertical midway line 16 between lower side surfaces and upper side surfaces. The rounded tongue edges 30, 32 and 34, connection 31 and corners 33 enhance movement of the tongue 18 within the cavity 36 and the dissipation of stress in an assembled mat, as discussed more fully below.
FIG. 4 shows cavity side surfaces 11 of a grid 4. The side surface 11 has an upper side surface 12 and a lower side surface 14 similar to that shown in FIG. 1, but contains a tongue receiving cavity 36 instead of a connecting tongue 18. The cavity 36, like the connecting tongue 18, is located at the center of the lower side surface 14 of the cavity side surface 11 and extends vertically from the bottom surface 8 of the grid 4 to approximately the vertical midway point 16. The cavity 36 has a cavity opening, a backwall 40, an upperwall 42, and a pair of parallel sidewalls 46a and b.
The cavity 36 is of sufficient size to allow full entry of the tongue 18 inside it, with additional room to allow slight movement of the tongue 18 once inside. The width and height of the cavity 36 is of sufficient size to allow entry of the front tongue surface 26 through it, as seen in FIG. 13. Likewise, the height of the cavity sidewalls 46a and b are of sufficient size to allow entry of the full side tongue surfaces 28a and b. A rounded upper cavity edge 43 is located between the upper side surface 12 and the upperwall 42 of the cavity 36. Preferably, the sidewalls 46a and b are downwardly sloping away from the upper wall 42, so that the cavity 36 forms a reverse image of the tongue.
FIGS. 5, 6 and 7 show types of blocks 2, used in the present invention; each type differing in the number of tongues 18 and cavities 36, but otherwise as described above.
FIG. 5 shows an interior block 2a having three adjacent tongue side surfaces 10 containing a first interior block tongue 5, a second interior block tongue 7 and a third interior block tongue 9; and three adjacent cavity side surfaces 11, containing a first interior block cavity 13, a second interior block cavity 15, and a third interior block cavity 17.
FIG. 6 shows an inner edge block 2b having a pair of adjacent tongue side surfaces 10, containing a first inner edge tongue 19 and a second inner edge block tongue 21; and four adjacent cavity side surfaces 11; containing a first inner edge block cavity 23, a second inner edge block cavity 25, a third inner edge block cavity 27, and a fourth inner edge block cavity 29.
FIG. 7 shows an outer edge block 2c having four adjacent tongue side surfaces 10 containing a first outer edge block tongue 31, a second outer edge block tongue 33, a third outer edge block tongue 35 and a fourth outer edge block tongue 37; and a pair of adjacent cavity side surfaces 11, containing a first outer edge block cavity 39 and a second outer edge block cavity 41.
To form a revetment mat, a number of blocks 2 are coupled together. FIG. 8 shows, in detail, a bottom perspective of a cluster of coupled blocks 2. The center block 80 is held in position, both horizontally and vertically, by the weight of the blocks 81-86 surrounding and coupled with the block 80. That is, the block 80 is held in stable horizontal position by the surrounding blocks 81-86, and cannot be moved out of its vertical coupled position because of the downward force of the surrounding blocks 2 on the tongues 18 of the block 80. Furthermore, each surrounding block 81 through 86 is likewise surrounded by other blocks 2, unless it is along an edge of a mat, in which case it is only partially surrounded. However, even the partially surrounded blocks 2 are held in position with the aid of the tongue 18 and cavity 36 coupling means. For extra stability, revetment ends and bottoms can also be buried in the subsoil and covered with stone. Also, anchoring means may be used to provide added stability to mats placed on slopes.
FIG. 9 shows an exploded view of one embodiment of a revetment mat constructed from the above-described blocks 2. To form the mat 56 a plurality of blocks 2 are interconnected by inserting the tongues of blocks 2 into the cavities of neighboring blocks 2. The mat 56, when completed, has an inner edge 58, an interior portion 60, an outer edge 62, an upper line 65 of cavities, and a lower line 61 of tongues, a first side line 67 of cavities, and a second side line 69 of tongues. The inner edge 58 is comprised of a plurality of inner edge blocks 2b, as shown in FIG. 6, connected to form a row of desired length. The row is formed when the first inner edge block tongue 19 of a first inner edge block 52 is coupled with the third inner edge block cavity 27 of a second inner edge block 53, and the first inner edge block tongue 19 of the second inner edge block 53 is coupled with the third inner edge block cavity 27 of a third inner edge block 55. Additional similar inner edge blocks 2b are present in the row so as to achieve a mat 56 of desired length. This results in each inner edge block 2b of the edge 58 having its first inner edge block cavity 23 and its second inner edge block cavity 25 adjacent to each other and opposite the interior portion 60 of the mat, and the second inner edge block tongue 21 and the fourth inner edge block cavity 29 facing the interior portion 60 of the mat 56.
A first interior block 48 is coupled with the inner edge 58 having coupled the first interior block tongue 5 of the interior block 48 to the fourth inner edge block cavity 29 of the second inner edge block 53, and the second inner edge block tongue 21 to the first interior block cavity 13 of the first interior block 48. A second interior block 49 is connected to the edge 58 by similarly being coupled with the second and third inner edge blocks 53 and 55 and further by having coupled the second interior block tongue 7 of the first interior block 48 to the second interior block cavity 15 of the second interior block 49. Further interior blocks 2a are connected to the inner edge blocks 2b in similar manner as desired. Interior blocks 2a may also be coupled with other interior blocks 2a to form the remainder of the interior portion 60 of the mat. The first interior block tongues 5 of interior blocks 2a are coupled with the third interior block cavities 17 of adjacent interior blocks 2a so as to form a mat of interconnecting blocks of desired surface area. Likewise, the second interior block tongue 7 of each interior block 2a is coupled with the second interior block cavity 15 of a neighboring interior block 2a.
The blocks forming the outer edge 62 of the mat 56 are attached to those forming the interior portion 60. Outer edge blocks 2c are connected to interior blocks 2a by coupling the first outer edge block tongue 31 of the first outer edge block 57 to the third interior block cavity 17 of the first interior block 48. The first outer edge block cavity 39 of the second outer edge block 59 is coupled with a third internal block tongue 9 of block 48. The second outer edge block tongue 33 of the first outer edge block 57 of the outer edge 62 is coupled with the second outer edge block cavity 41 of the next succeeding outer edge block 59. Additional outer edge blocks 2c are similarly present to form the outer edge 62.
Each block 2 may optionally be provided with a through tunnel 70 which begins on the front tongue surface 26, passes through the grid 4, and exits on the backwall 40 of a tongue receiving cavity 36 directly opposite the tunneled tongue surface 26. As shown in FIG. 9, for the first interior block 48 which is an inner edge block 2b, the tunnel 70 begins on the second interior block tongue 7 and exits on the backwall 40 of the second interior block cavity 15. On the inner edge block 52, which is an interior block 2a, the tunnel 70 begins on the first inner edge block tongue 19 and exits on the backwall 40 of the third inner edge block cavity 27. On the first outer edge block 57, which is an outer edge block 2c, the tunnel 70 begins on the second outer edge block tongue 33 and exits on the second outer edge block cavity 41. In each block 2, the tunnel 70 is located at a uniform location on both the front tongue surface 26 and the backwall 40 so as to allow the tunnel 70 of a first block 2 to align with the tunnel 70 of a second, interconnected block 2. Additionally, the uniformity of tunnel 70 location allows grids 4 of varying height and weight, as shown in FIG. 11, to be interconnected as desired.
Cables, or rods, preferably plastic, stainless steel, or other non-corrosive material, may be inserted through the tunnels 70 to provide additional stability to mats 56. The cable 45 has minimal exposure to sunlight or the elements because the point where it leaves one block 2 and enters a second block 2 is within a cavity 15.
FIG. 10 illustrates an assembled mat 56, either preassembled or assembled on-site. When assembly is done on-site, a base block 101 is set at a desired position. Preferably, the base block 101 is set at the point corresponding to offshore limit of the revetment and the revetment is assembled by working towards the shoreline. A second block 102 is positioned a distance equivalent to a block 2 width laterally away from the base block 101. A third block 103 is then coupled with base block 101 and block 102 as shown. A fourth block 104 is similarly set a block 2 width laterally away from block 102, and a fifth block 105 is coupled with block 102 and block 104. This procedure is repeated laterally, until a mat edge of desired length is achieved. Thereafter, another row of blocks is formed by coupling a block 100 to blocks 101 and 103, as shown. Block 109 is coupled to blocks 102, 103 and 105. Block 110 is then coupled to blocks 104, and 105. This procedure is also repeated laterally to form additional rows of blocks 2. By following this sequence, the blocks 2 can be maneuvered to allow easy insertion of tongue into cavities as an entire mat 56 is assembled.
Once assembled either on-site or off-site, cables not shown, preferably of plastic or other non-corrodable material, may be passed through the tunnels 70, shown in FIG. 9, of the interconnected blocks 2 to provide stability beyond the tongue 18 and cavity 36 connecting means. The cable 45 has minimal exposure to sunlight and the elements because the points where the cable 45 leaves one block 2 and enters a second block 2 is within a cavity 15. The mat 56 may also be lifted with parallel cables passed through the tunnels 70. This will provide a good catenary curve to the mat 56 during lifting, and encourages cavities 36 to fall clearly over tongues 18 of adjacent mats 56 during assembly.
Optionally, as illustrated in FIG. 10, second holes 43 may be provided through the grids 4 at points above the tongues 18 and cavities 36 of the block 2. These second holes 43 are placed so that a cable 45 or rod may be placed in a second, diagonal position through the assembled blocks 2, and, either alone or in combination with through tunnel 70, shown in FIG. 9, provide added stability to the mat 56. The mat 56 can be therefore optionally assembled block by block at the point of use, or can be pre-assembled and positioned as a unit. When pre-assembly is desired, the cables 45 at the ends of the assembled mat can be hooked to a doublebar strongback so as to allow the mat 56 to be lifted by a crane and placed in final position. The use of cables 45 to connect the blocks 2 provides sufficient stability during lifting. The hexagonal shapes of the grids 4 results in a mat 56 of good catenary curve when lifted, and encourages cavities 36 to fall cleanly over tongues 18 of adjacent mats 56.
Because of the stability provided by the interlocking tongue and groove connections, mats may be formed using no cables or a minimal number of cables 45. For example, a mat may be reinforced with a plurality of loops. The parallel placing of the loops as they enter the preassembled mat enables the mat to be lifted uniformly and without distortions. This will prevent excess strain on the interlocking blocks. Also, for maximum stability, the points at which the cables are lifted should be on the same axis as the point where the cables enter the block 2.
The size of the revetment may be increased by joining preassembled mats 56 together, as shown in FIG. 10. The width of the revetment may be increased by attaching the upper edge 65 of an already positioned first mat 56a to the lower edge 61 of a second, preassembled mat 56b. Similarly, the length of the revetment may be increased by attaching the first side line 67 of a mat 56b to the second side line 69 of tongues of an already positioned mat 56b. Additional preassembled mats 56 can be further added to cover the surface area as necessary. For additional strength, the mats 56 may be connected in a staggered manner.
An end block may be used either at the end of an assembled revetment, so as to reduce the total surface area of the block and thereby minimize hydrostatic pressure, or an inner edge block when lateral cables are used to connect serially connected mats. The end block is hexagonal-shape and has a pair of tongue side surfaces separated by a single cavity side surface. The remaining three adjacent sides are also cavity side surfaces. A through tunnel may extend through the block beginning at the single cavity side surface between the two tongue side surfaces, and ending at the surface opposite the single cavity side surface. In this way, cables may optionally be placed laterally through the mat for further stability. Mats having edges formed by end blocks can be tied together by swaging plastic, and the splices may be grouted in the cavities to avoid vandalism and provide tight connections. Also, an opened block 2d, as seen in FIG. 6a, may be provided. The opened block 2d is used similarly to inner edge block 2b, but has a pair of opened, adjacent grooves 112 and 114 for allowing easier connecting of mats 56 having knotted cable lines along their edges. The grooves 112 and 114 also make grouting of the connections an easier task.
If the mat 56 is to be assembled on site, the outer edge blocks 2c and the inner edge blocks 2b may be omitted and only the interior blocks 2a used. Also, unless there is a need for enhanced stability, the cables 45 may be omitted and the tongue 18 and cavity 36 connecting means relied on to hold the mat 56 together. Other than the optional cables 45, no auxiliary components are needed to hold the mat 56 together. This results in increased effectiveness in both time and cost.
FIG. 12 shows a cross-sectional view of three coupled blocks 2. A tongue 18 is inserted into a cavity 36, thereby interlocking two blocks. A first space 47 is formed between the sloped front tongue surface 26 and the vertical backwall 40. A second space 49 is formed between the sloped top tongue surface 24 and the adjacent horizontal ceiling 42 of the cavity 36. A third space 51 is formed between the sloped upper side surface 12a of the first block 2 and the sloped upper side surface 12b of the second block 2. As shown in FIG. 13, which is an underneath perspective view of a tongue 18 within a cavity 15, the width of the tongue 18 is less than the width of the cavity 36, so that a fourth space 55 is formed between the side tongue surfaces 28a and b and the sidewalls 46a and b of the cavity 36. The spaces 47, 49 and 55 allow the tongue 18 to move slightly within the cavity 36 while remaining coupled both vertically and horizontally by the presence of the grid 4 around the cavity 36. The space 51 allows one block 2a to pivot slightly at its midpoint 16 in relation to its neighboring block 26. These slight movements prevent any one tongue 18 from taking the entire destructive force during water impact. This is especially important when the blocks 2 are made of concrete, which is low in tensile strength.
The slight movement of the blocks 2 within the mat 56 also creates space 57 between lower side surfaces 14 of adjacent blocks 2. This space 57, as well as the holes 50 of the grid 4, provide relief from hydrostatic pressure when the mat 56 is subject to force, for example, during high and low frequency wave attack. The holes 50 and spaces in the mat 56 also reduce downstream water velocities due to eddy currents and provide a means of easy draw-down of adjacent high water tables after storms. An advantage gained is that the increase in resistance decreases the length of revetment needed. The rounded tongue edges 30, 32, 34a and b, enhance the movement between blocks 2. The flexibility also permits the mat 56 to adjust to the topographic features of the riverbank or beach.
Referring again to FIG. 13, bottom surface 8 of the grid 4 and bottom tongue surfaces 22 form one continuous flat surface. This results in the mat 56 having a flat bottom surface which, in conjunction with the flexibility of the mat 56 described above, results in minimizing space between the bottom surface and the subsoil. This reduces hydraulic lifting of the blocks 2. Also, if any hydraulic lift does occur, the blocks 2 cannot become dislodged vertically or horizontally due to the mating of the tongues 18 of each block with the cavities of adjacent blocks 36.
FIGS. 11 and 14, show typical shoreline profiles of mats 56. The mat 56 may be placed either directly on the subsoil 62, on a filter fabric 60 to discourage erosion of subsoil, or on other filter means. As stated above, blocks 2 of varying thickness may be utilized by providing tunnels 70, shown in Fig. 9, or holes 43, shown in FIG. 10, on equal planes throughout the blocks 2, and by providing identically sized tongues 18 and cavities 36. Preferably, blocks 2 of varying heights and weights are alteringly positioned in deeper water to provide higher coefficient of roughness to the mat surface to slow the flow of water over the mat towards the shore line, as shown in FIG. 14. This increases the ability of the mat to withstand wave attack by dissipating kinetic energy before the wave attack reaches the main line revetment.
While the above description contains many specifications these should not be construed as limitations on the scope of the invention, but rather as an amplification of one preferred embodiments thereof. For example, the size of blocks can vary depending upon application.
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A flexible revetment mat used to control soil erosion comprised of a plurality of blocks each having a hexagonally shaped grid held firmly together by tongue and cavity coupling means. The tongues and cavities are shaped to allow limited movement of each tongue within its associated cavity. The blocks may be placed into position with or without connecting cables. The shape of the blocks and location of through tunnels allows the use of cables. The blocks are preferably hexangular to resist horizontal hydraulic forces at various directions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Korean Patent Application No. 10-2004-0096168, filed on 23 Nov. 2004, the content of which is incorporated by reference in its entirety for all purposes.
BACKGROUND
1. Technical Field
This disclosure relates to a method of fabricating semiconductor memory devices, and more particularly, to a method of fabricating static random access memory devices.
2. Discussion of Related Art
Generally, static random access memories (SRAMs) have been widely used in a field of middle-or small-sized computers because the memories operate at a high speed despite lower integration compared to dynamic random access memories (DRAMs). A conventional SRAM cell is typically composed of a flip flop circuit that includes two transfer transistors, two driver transistors, and two load elements. Information is represented as a difference in voltage between the input and output terminals of the flip flop, i.e., charges accumulated on a node of the cell. The charges are always supplemented via a PMOS transistor or a load resistor as a load element from power supply voltage (Vcc), and thus, unlike DRAMS, SRAMs need not have a refresh function.
SRAM memory cells may be further classified as either high-resistance cells that utilize a high resistance load element or as Complementary Metal Oxide Semiconductor (CMOS) cells that utilize a P-channel Metal Oxide Semiconductor (PMOS) transistor as the load element.
CMOS cells may be further classified as either thin film transistor cells that utilize a thin film transistor as the load element or as complete CMOS cells that utilize a bulk transistor as the load element.
FIG. 1 is a circuit diagram illustrating a conventional CMOS cell.
Referring to FIG. 1 , the CMOS cell 100 is composed of a pair of driver transistors TD 1 and TD 2 , a pair of transfer transistors TA 1 and TA 2 , and a pair of load transistors TL 1 and TL 2 . The driver transistors TD 1 and TD 2 and the transfer transistors TA 1 and TA 2 are N-channel Metal Oxide Semiconductor (NMOS) transistors while the load transistors TL 1 and TL 2 are both PMOS transistors.
The first driver transistor TD 1 and the first transfer transistor TA 1 are connected in series. A source region of the first driver transistor TD 1 is connected to a ground line Vss and a drain region of the first transfer transistor TA 1 is connected to a first bit line BL.
Similarly, the second driver transistor TD 2 and the second transfer transistor TA 2 are connected in series. A source region of the second driver transistor TD 2 is connected to the ground line Vss and a drain region of the second transfer transistor TA 2 is connected to a second bit line /BL. The first and second bit lines BL and /BL carry opposite information. That is, if the BL is at logic “1,”/BL is at logic “0.”
A source region of the first load transistor TL 1 is connected to a power line Vcc. A drain region of the first load transistor is connected to a drain region of the first driver transistor TD 1 . In other words, the drains of the transistors TL 1 and TD 1 share a common first node.
Similarly, a source region of the second load transistor TL 2 is connected to the power line Vcc and a drain region of the second load transistor is connected to a drain region of the second driver transistor TD 2 . In other words, the drains of the transistors TL 2 and TD 2 share a common second node.
A gate electrode of the first driver transistor TD 1 and a gate electrode of the first load transistor TL 1 are both connected to the second node. A gate electrode of the second driver transistor TD 2 and a gate electrode of the second load transistor TL 2 are both connected to the first node. In addition, gate electrodes of the first and second transfer transistors TA 1 and TA 2 are connected to a word line WL.
SRAMs may often be multi-layered to achieve high integration of semiconductor devices.
FIGS. 2A-2D are sectional diagrams illustrating a conventional method of fabricating an SRAM.
Referring to FIG. 2A , a conductive layer (not shown) is deposited on a semiconductor substrate 1 . A gate line 2 is formed using by performing a photolithographic process on the conductive layer. An insulating sidewall 3 is then formed on a side surface of the gate line 2 using an etch back process.
A first insulating film 4 is formed on surface of the semiconductor substrate and on the gate line 2 , and then a first interlayer insulating film 5 is formed on the first insulating film 4 . The first insulating film 4 prevents diffusion of impurities in a device, such as an SRAM, and may also be used as an etch stopping layer in an etching process. The first insulating film 4 is composed of SiOn or SiN. The first interlayer insulating film 5 is an interlayer dielectric (ILD) film (oxide film).
Photoresist is then deposited on the first interlayer insulating film 5 . Using exposing and developing processes, a photoresist pattern PR is formed with a uniform interval.
As shown in FIG. 2B , the first interlayer insulating film 5 and the first insulating film 4 are selectively removed using the photoresist pattern PR as a mask.
As shown in FIG. 2C , using selective epitaxial growth (SEG), a single crystalline silicon layer 8 is grown in a region 7 defined by the photoresist pattern PR.
Pre-flow of silane (SiH 4 ) is carried out on the first interlayer insulating film 5 and the single crystalline silicon layer 8 . This prevents a natural oxide film, such as silicon dioxide (SiO 2 ), from forming on the first interlayer insulating film 5 and the single crystalline silicon layer 8 .
As shown in FIG. 2D , a process temperature is elevated to a predetermined temperature and then an amorphous silicon layer 9 is deposited on the first interlayer insulating film 5 and the single crystalline silicon layer 8 using a suitable method, e.g., sputtering, plasma enhanced chemical vapor deposition (PECVD), or low-pressure chemical vapor deposition (LPCVD). The amorphous silicon layer 9 is annealed in order to become crystallized. The single crystalline silicon layer 8 serves as a seed for crystallization of the amorphous silicon layer 9 . The crystallized silicon layer serves as channel silicon.
Unfortunately, during the annealing of the amorphous silicon layer 9 , a thinning phenomenon may occur such that the resulting crystallized silicon layer has a thinned profile in a region around the single crystalline silicon layer 8 .
FIG. 3 is a photograph illustrating the thinning phenomenon in which the crystallized silicon layer has a thin profile in a region 11 around a single crystalline silicon layer. This reduction in thickness of the crystallized silicon layer is undesirable because the thinner portion of the silicon layer may be removed during subsequent processes.
Embodiments of the invention address these and other disadvantages of the conventional art.
SUMMARY
Embodiments of the invention may reduce the occurrence of a thinning phenomenon in a silicon layer by recessing the ILD and depositing an amorphous silicon layer at low temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram illustrating a conventional CMOS cell.
FIGS. 2A-2D are sectional diagrams illustrating a conventional method of fabricating an SRAM.
FIG. 3 is a photograph illustrating a thinning phenomenon resulting from the conventional method illustrated in FIGS. 2A-2D .
FIGS. 4A-4E are sectional diagrams illustrating a method of fabricating an SRAM according to some embodiments of the invention.
FIG. 5 is a graph illustrating the reduction in the thinning rate associated with some embodiments of the invention.
FIG. 6 is a graph illustrating the reduction in the thinning rate that is associated with some other embodiments of the invention.
DETAILED DESCRIPTION
Preferred embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings. The invention may, however, also be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided as teaching examples of the invention. Like numbers refer to like elements.
According to embodiments of the invention, a first interlayer insulating film is recessed through etching and then an amorphous silicon layer is deposited on the first interlayer insulating film and a single crystalline silicon layer at low temperature.
FIGS. 4A-4E are sectional diagrams illustrating a method of fabricating an SRAM according to some embodiments of the invention.
A shown in FIG. 4A , a conductive layer (not shown) is deposited on a semiconductor substrate 101 . A gate line 102 is formed by performing a photolithographic process on the conductive layer. An insulating sidewall 103 is then formed on a side surface of the gate line 102 using an etch back process.
A first insulating film 104 is formed on a surface of the semiconductor substrate and on the gate line 102 . A first interlayer insulating film 105 is formed on the first insulating film 104 .
The first insulating film 104 may prevent diffusion of impurities in a device, such as an SRAM, and may also be used as an etching stopping layer in an etching process. The first insulating film 104 may be composed of SiON, SiN, or a similar material. The first interlayer insulating film 105 may be an interlayer dielectric (ILD) film that is composed of an oxide film.
Photoresist is then deposited on the first interlayer insulating film 105 . Using exposing and developing processes, a photoresist pattern PR is formed with a uniform interval.
As shown in FIG. 4B , the first interlayer insulating film 105 is selectively removed using the photoresist pattern PR as a mask, so that a contact is formed.
As shown in FIG. 4C , a single crystalline silicon layer 108 is grown in a region 107 defined by the photoresist pattern using selective epitaxial growth (SEG).
As shown in FIG. 4D , the first interlayer insulating film 105 surrounding the single crystalline silicon layer 108 is recessed by etching. This process may be referred to as an Inter-Layer Dielectric (ILD) recess process. Next, a pre-flow of silane (SiH 4 ) is carried out on the first interlayer insulating film 105 and the single crystalline silicon layer 108 .
As shown in FIG. 4E , an amorphous silicon layer 109 is deposited on the first interlayer insulating film 105 and the single crystalline silicon layer 108 using a suitable method (e.g., a method such as sputtering, PECVD, or LPCVD). Before the amorphous silicon layer 109 is deposited, the process temperature is preferably set to a predetermined temperature. The predetermined temperature preferably ranges from about 450° C. to about 500° C. After the deposition process, the amorphous silicon layer 109 preferably covers a top surface of the single crystalline silicon layer 108 and partially covers the side surfaces of the single crystalline silicon layer.
An annealing process is then performed on the amorphous silicon layer 109 so that it becomes crystallized. Here, the single crystalline silicon layer 108 serves as a seed for crystallization of the amorphous silicon layer 109 . The crystallized silicon layer 109 serves as channel silicon.
Depositing and annealing the amorphous silicon layer following the ILD recessing reduces the occurrence of the thinning phenomenon.
FIG. 5 is a graph illustrating the reduction in the thinning rate associated with some embodiments of the invention. In particular, FIG. 5 illustrates the reduction in thinning rate that can be achieved using the ILD recess process according to some embodiments of the invention. As shown in FIG. 5 , the thinning rate for the crystallized silicon layer is about 70% when the conventional process is used. On the other hand, when the ILD recess method according to some embodiments of the invention is used, the thinning rate drops to about 30%. The thinning rate indicates to what extent the thickness of the crystallized silicon layer is reduced in the area around the single crystalline silicon layer. As shown in FIG. 5 , the ILD recess process according to some embodiments of the invention reduces the thinning rate.
FIG. 6 is a graph illustrating the reduction in the thinning rate that is associated with some other embodiments of the invention. In particular, FIG. 6 illustrates the thinning rate of the silicon layer as a function of the deposition temperature of the amorphous silicon layer. FIG. 6 illustrates that as the deposition temperature for the amorphous silicon layer is reduced, the thinning rate is reduced as well. Thus, according to other embodiments of the invention, it is possible to further reduce the thinning rate by using the ILD recess process described above in conjunction with lowering the deposition temperature of the amorphous silicon layer.
The invention has been described above using preferred exemplary embodiments. However, it is to be understood that the scope of the invention is not limited to the disclosed embodiments. To the contrary, the scope of the invention is intended to include various modifications and alternative arrangements within the capabilities of persons skilled in the art using presently known or future technologies and equivalents. The scope of the claims, therefore, should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A method of fabricating a static random access memory device includes selectively removing an insulating film and growing a single crystalline silicon layer using selective epitaxy growth, the single crystalline silicon layer being grown in a portion from which the insulating film is removed; recessing the insulating film; and depositing an amorphous silicon layer on the single crystalline silicon layer and the insulating film, such that the amorphous silicon layer partially surrounds a top surface and side surfaces of the single crystalline silicon layer.
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FIELD OF THE INVENTION
This invention relates to modified polytetrafluoroethylene (PTFE) fine powder compositions and the preparation thereof and articles formed therefrom. More particularly, this invention relates to PTFE fine powder compositions which contain a small amount of at least one selected dioxole copolymerized therewith, and to processes for preparing such compositions.
BACKGROUND OF THE INVENTION
Polytetrafluoroethylene fine powder compositions are non-melt-fabricable and are commonly processed by paste extrusion wherein the powder is mixed with a lubricant and is then discharged through a paste extruder die to obtain films, tubes, tapes, protective coating on wire and the like.
To make "fine powder" PTFE, a process called "aqueous dispersion polymerization" is used. In this process sufficient dispersing agent is employed under mild agitation in order to produce small colloidal size particles dispersed in the aqueous reaction medium. In this procedure precipitation (i.e., coagulation) of the resin particles is avoided during polymerization. The dispersion may be used as such, or the dispersed particles may be coagulated in a separate step and the resulting fine powder obtained.
There is another PTFE material that is referred to by those skilled in the art as "granular" PTFE. Granular PTFE resins are employed in molding and ram extrusion processes to produce plastic articles, but cannot be paste extruded. They are prepared by "suspension polymerization" which involves polymerizing repeat units of tetrafluoroethylene (TFE) monomer in the presence of little or no dispersing agent and vigorously agitating the resulting polymer in order to produce a precipitated resin.
It has previously been known that if a small amount of repeat units of copolymerizable monomer is added to the repeat units of TFE monomer in preparing granular PTFE, the properties of the PTFE particles can be altered. U.S. Pat. No. 3,978,030 is directed to a copolymer of a dioxole and either chlorotrifluoroethylene, hexafluoropropylene, or TFE. However, a paste extrudable dioxole modified fine powder resin with superior tensile properties is not disclosed or suggested. U.S. Pat. No. 4,399,264 concerns a copolymer of perfluorodioxole (PD) and TFE. However, this reference does not disclose or suggest a PTFE core/shell fine powder composition with PD confined to a core portion and a shell portion free of PD.
It is an object of the present invention to provide a PTFE resin that is a clear, transparent material suitable for coating surfaces. It is a further object of this invention that such a material be capable of pigmenting to produce a variety of colorful coatings. These and other objects, features and advantages will become apparent in the description that appears below.
SUMMARY OF THE INVENTION
This invention is a modified dispersion-process-produced PTFE fine powder composition comprising a core portion and a shell portion. The core portion contains a copolymer comprising repeat units provided by a TFE monomer and repeat units provided by at least one copolymerizable monomer of the formula ##STR1## wherein X and X' are selected from the group consisting of F, Cl and H, and Y is selected from the group consisting of ##STR2## wherein Z and Z' are selected from the group consisting of F, alkyl units having from 1 to 6 carbon atoms, and fluorinated alkyl units having from 1 to 6 carbon atoms. The shell portion is substantially free of dioxole units.
DETAILED DESCRIPTION OF THE INVENTION
The monomers according to the invention and that are copolymerizable with TFE monomer are present in the copolymer chain formed therein in random recurring amounts that are small enough that their presence does not make the polymer melt-processible. The dioxole monomer is relatively highly reactive and is confined to the particle interior, and so is added as a precharge. The composition may also include other perfluoromonomers specified below during polymerization. They have low reactivities and, if used, will be present in both the core portion and the shell portion of the composition.
Particle size in the dispersion can be controlled by known procedures. For example, addition of dispersing agent can be programmed as taught in U.S. Pat. No. 3,391,099 to increase size. Generally, product particle size in the dispersion will be between 0.1 and 0.5 micrometer.
The polymerization initiator may also be added to the composition as a precharge, in increments, continuously, or in some combination thereof. The initiator can be added in an initiating amount; that is, any amount at least sufficient to promote initiation of the polymerization. The initiator can be one or more of any of the usual initiators for TFE monomer polymerization, such as ammonium persulfate (APS), potassium persulfate (KPS), disuccinic acid peroxide (DSP), a redox combination of potassium permanganate/oxalic acid and the like. Generally the initiator is used at 30-300 ppm based on water.
A dispersing agent is added to the reaction medium. It can be any of the common non-telogenic dispersing agents used in dispersion polymerization of TFE monomer. This agent may be present in a dispersing amount; that is, any amount at least sufficient to promote dispersion. The amount will be sufficient to stabilize the polymer particles in the dispersion and to keep coagulum formation at a minimum. Ammonium perfluorooctanoate (commonly called C-8) is preferred. C-8 concentrations of 0.1 to 0.5 weight percent, based on aqueous charge, are normally used.
Fine powder is obtained from the dispersion by coagulation to form agglomerates of primary particles that have an average particle diameter of 0.1 to 0.5 micrometers. Coagulation can be affected by agitation or by addition of an electrolyte.
The modified PTFE polymers according to this invention are readily processible and can be paste extruded into products such as wire insulation and tubing. Such polymers are also transparent, and thus function as a clear coating on a substrate. These clear compositions can be pigmented for a colorful appearance.
The composition according to the invention may contain repeat units provided by additional copolymerizable monomers in the core and/or shell portions. These additional copolymerizable monomers include perfluoro (n-alkyl vinyl) ether monomers of the formula R' f --O--CF═CF 2 , where R' f is a normal perfluoroalkyl radical of from 1 to 5 carbon atoms, preferably 1-3 carbon atoms. In a most preferred embodiment of the invention, the perfluoro (n-alkyl vinyl ether) monomer is perfluoro(n-propyl vinyl ether) (PPVE).
The copolymerizable monomer having the formula ##STR3## as defined earlier is known as a dioxole monomer. A preferred dioxole monomer according to the invention is perfluoro-2,2-dimethyl-1,3-dioxole.
The total amount of all comonomers is less than 0.5 weight percent based on composition weight.
One embodiment of the invention features a primary particle size of between 0.1 and 0.5 micron, a standard specific gravity (SSG) of less than 2.20, maximum tensile stress greater than 19.6 MPa, and break elongation in excess of 300 percent.
The process according to the invention involves the dispersion polymerization of repeat units provided by TFE monomer in the presence of repeat units provided by dioxole monomer, in an aqueous medium and optionally in the presence of repeat units provided by an additional copolymerizable monomer such as perfluoro(n-alkyl vinyl)ether (and preferably PPVE) monomers. The dioxole monomer is added to the TFE monomer as a precharge and such that it is confined to the core portion of the composition. However, the additional copolymerizable monomer may be added to the system so that it may be present in both core and shell portions. The shell portion is substantially free of dioxole units. The polymerization is carried out in an aqueous medium in the presence of an initiating amount of a polymerization initiator and a dispersing amount of a dispersing agent at a temperature below 125° C. at a pressure (of TFE) of 7-40 kg/cm 2 (0.7-4.0 MPa).
The polymerization is carried out in a gently agitated aqueous medium. The medium will contain a non-telogenic dispersing agent such as ammonium perfluorooctanoate. The ammonium perfluorooctanoate is partly precharged in 0.003-0.1 weight percent concentration based on aqueous charge, with the balance added either intermittently or continuously during polymerization to a total concentration of 0.1-0.5 weight percent.
The process according to the invention is typically carried out at a temperature of between 50° and 100° C. A high quality wax is used to control coagulum formation in the high solid dispersion.
TESTING INFORMATION
Several properties of the polymers of this invention are determined according to procedures described as follows:
(1) Determination of perfluoro(n-propyl vinyl)ether (PPVE) Content in the Polymer
The PPVE content was determined by Fourier Transform (FT) IR spectroscopy. The C--O--C band at 995 cm -1 was used. A 0.3 g sample of the polymer was leveled between pieces of aluminum foil in a cylindrical mold, 2.86 cm in inside diameter. A pressure of 1409 kg/cm 2 (138 MPa) was applied for one minute at ambient temperature. The pressed sample, which was 0.025 cm thick, was then analyzed by IR. The sample was scanned from 1040 to 877 cm -1 . A straight base line was drawn from the absorbance minimum at 1010 cm -1 to that at 889 cm -1 . The ratio of the absorbance from the base line to the maximum at 995 cm -1 to the absorbance from the base line to the maximum at 935 cm -1 was obtained. The actual weight percent PPVE was determined from a calibration curve or by multiplying the ratio by the following factor:
______________________________________Absorbance Ratio Factor______________________________________0.01 0.400.02 0.300.04 0.250.08 0.19______________________________________
(2) Determination of Perfluoro-2,2-dimethyl-1,3-dioxole (PDD) Content in the Polymer
The dioxole content was also determined by FT IR spectroscopy. The perfluoroether band at 988 cm -1 was used. The IR was calibrated against Nuclear Magnetic Resonance (NMR). The ratio of the absorbance at 988 cm -1 to that at 935 cm -1 was multiplied by a factor of 0.1053 to obtain percent dioxole by weight.
(3) Standard Specific Gravity
Standard Specific Gravity (SSG) was measured by water displacement of a standard molded test specimen in accordance with ASTM D1457-69. The standard molded part was formed by preforming 12.0 g of the powder in a 2.86 cm diameter die at a pressure of 352 kg/cm 2 (35 MPa), followed by the sintering cycle of the preform of heating from 300° C. to 380° C. at 2° C./minute, holding at 380° C. for 30 minutes, cooling to 295° C. at 1° C./minute and holding at this temperature for 25 minutes, after which the specimen was cooled to 23° C. and tested for specific gravity.
(4) Raw Dispersion Particle Size (Average)
Raw Dispersion Particle Size (RDPS) was determined from the absorbance (scattering) of a dilute aqueous sample at 546 millimicrons using a Beckman DU spectrophotometer and is based on the principle that the turbidity of the dispersion increases with increasing particle size, as shown in U.S. Pat. No. 4,036,802.
(5) Tensile Stress and Elongation
Tensile stress and elongation were determined by the method described in ASTM D1457-75. A preform pressure of 13.8 MPa was used.
EXAMPLES
Example 1
A 36-liter polykettle vessel was charged with 20.9 kg of demineralized water, 600 g of paraffin wax, 5.0 g of ammonium perfluorooctanoate dispersant. The contents of the vessel were heated to 65° C., evacuated, and purged with TFE monomer. Thereafter, 14.0 g of PDD and 19.9 g of PPVE were added to the vessel. The contents of the vessel were agitated at 46 rpm. The temperature was increased to 80° C., and TFE monomer was then added to the vessel until the pressure was 2.61×10 6 Pa. A 180 ml (1 g/l) solution of ammonium persulfate (APS) initiator was injected into the vessel at 90 ml/min. The polymerization began after the start of the initiator injection, as evidenced by a drop in pressure. TFE monomer was added to the vessel to maintain the pressure. After 1.36 kg of TFE monomer had reacted, a solution of 28 g of ammonium perfluorooctanoate in 1000 ml aqueous solution was pumped into the vessel at 50 ml/min.
Polymerization was continued until 11.8 kg of TFE monomer had reacted; thereafter the vessel was vented, evacuated, and purged with N 2 . The contents were discharged from the vessel and cooled. The supernatant wax was removed from the dispersion. The dispersion was diluted to 15% solids with water and coagulated in the presence of ammonium hydroxide under high agitation conditions. The coagulated fine powder was separated and dried at 150°-160° C. for three days.
The dispersion had an RDPS of 0.210 micron. The resin had an SSG of 2.155. The comonomer contents could not be determined accurately due to close absorption frequencies of repeat units of PDD and PPVE. The maximum tensile stress was 29.0 MPa and break elongation was 339%.
Comparative Example 1
Example 1 was repeated except that 33.7 g of PPVE was used as a copolymerizable monomer and no PDD was added to the polymer.
The dispersion had an RDPS of 0.156 micron. The resin had an SSG of 2.155 and a PPVE content of 0.114 weight percent. The maximum tensile stress was 25.6 MPa and break elongation was 278%.
A comparison of Example 1 to Comparative Example 1 reveals that the tensile properties of a resin modified with both PPVE and PDD are superior to those of the same resin modified with PPVE alone. Compare tensile stress and elongation of the dioxole modified resin (29.0 MPa and 339%) to those of the resin not modified with dioxole (25.6 MPa and 278%).
Example 2
The vessel of Example 1 was charged with 21.4 kg of demineralized water, 600 g of paraffin wax, and 30 g of C-8. At a temperature of 65° C., the vessel was evacuated and purged with N 2 . Thereafter, 14.3 g of PDD was precharged into the vessel after the final evacuation. The vessel was agitated at 46 rpm, and the temperature was increased to 90° C. The vessel was pressurized with TFE monomer to 2.75 MPa. A mixture of 0.1 g of APS and 10 g of DSP dissolved in 500 ml of water was added to the vessel at 90 ml/min. After 11.8 kg of TFE monomer had been reacted, the vessel was vented. The dispersion was treated as in Example 1.
The dispersion had an RDPS of 0.210 micron. The resin had an SSG of 2.163 and a PDD content of 0.088%. The maximum tensile stress was 27.2 MPa and break elongation was 382%.
Comparative Example 2
Example 2 was repeated except that 14.4 g of perfluorobutyl ethylene were precharged into the vessel instead of the PDD.
The dispersion had an RDPS of 0.136 micron. The resin had an SSG of 2.161. The maximum tensile stress was 23.8 MPa and break elongation was 344%.
A comparison of Example 2 to Comparative Example 2 reveals that the tensile properties of a resin modified with PDD are superior to those of the same resin modified with PFBE. Compare tensile stress and elongation of the dioxole-modified resin (27.2 MPa and 382%) to those of the PFBE-modified resin (23.8 MPa and 344%).
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A modified fine powder polytetrafluoroethylene, and the process for preparing the polymer, in which the modifying copolymerizable monomer is a selected dioxole monomer. The composition is dispersion-process-produced and includes a core portion having a copolymer comprising repeat units provided by tetrafluoroethylene monomer and dioxole monomer, and a shell portion that is substantially free of dioxole units. The core and shell portions may contain perfluoro (n-propylvinyl) ether. The composition is useful for paste extrusion, such as in wire coating and tubing applications.
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FIELD OF THE INVENTION
[0001] This invention relates to buildings structure.
BACKGROUND
[0002] Multi-storey buildings across roads have been built; however each of the structures built on each side of the road are of substantial size as is the middle structure bridging the two side buildings that is over the road. The middle building mainly serves as a passageway to connect the two side buildings, while the offices and parking garages are on the side buildings.
[0003] To the best of our knowledge there are no multi-storey buildings, built on columns situated either on the edge of sidewalks, on the medians separating driving lanes or both.
[0004] Autonomous driverless vehicles have been proposed and some have been tested on the roads. However the design goal of these autonomous vehicles is to replace the human driver on the road; as such they include sensors to image and check the surroundings around the vehicle and a controller to quickly react to changes and adapt the speed, steering and brakes of the vehicle.
[0005] The general purpose autonomous vehicle has to respond to the plethora of situations that a human driver may encounter during extended driving, even when the odds of such situations are very small.
[0006] Our purpose in automated driverless parking is much limited, it is driving for several minutes at very low speed along a predetermined route, at low and steady speed and have a very high maneuvering capabilities, that enable parking in minimal spaces.
SUMMARY OF THE INVENTION
[0007] The invention describes the building of multi-storey parking garages, residential and office buildings or a combination thereof, on the air-space above streets and roads, on long-span beams laid on cornerstone foundation supports of minimal cross-sections, on the opposite sidewalks of said streets and/or the medians separating street lanes.
[0008] In the case of a structure built on the air-space above an intersection of roads, the cornerstone foundation supports of minimal cross-sections, may be placed at the corner edges of the sidewalks around the intersection and/or at a median separating lanes. When the span between the sidewalk cornerstone foundation supports is large, an additional support column placed in the middle of the intersection helps support the structure. Consecutive floors of the structure are built in the same manner by laying large span steel beams, with or without concrete, so as to optimize the strength, flexibility and compression of the floor, depending its usage.
[0009] The cornerstone foundation supports may be linked by a reinforced concrete layer under the intersection roads, thus reinforcing the integrity of the building. Support columns situated on the medians between lanes may also be used to support the structure on the air-space.
[0010] Such buildings are advantageous mainly in mid-cities where real-estate land is practically unavailable or extremely expensive.
[0011] Parking garages built on road intersections serve to alleviate the need for parking spaces that are extremely scarce in mid-cities and also alleviate traffic bottlenecks on road intersections.
[0012] Such parking garage structures allow access from all directions and exits onto different directions, after parking or without it, while leaving at least one lane for pass-through crossing the intersection. The over the air-space parking garage also duplicates what the traffic lights do and consequently may in some cases eliminate the need for traffic lights at the intersection. An intersection with traffic lights may be converted onto a roundabout without traffic lights. Multi-storey parking garages may specifically be adapted to autonomous driverless vehicles as the route in the garage, to a preassigned parking place is well determined in advance, with no need for maneuvering the car, that requires human decisions. A highly maneuverable robotic trolley may carry the vehicle, to its parking place and back, thus relieving the human driver of the chore to park his car. Sensors pre-installed in the multi-storey garage supplement the capabilities of the robotic trolley and enable to safely bring the vehicle into its designated place, which may be reserved in advance, through the internet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a multi-storey building erected on 4 cornerstone foundation supports situated on the 4 sidewalks of the street intersections and a central support column.
[0014] FIG. 2 illustrates a multi-storey building erected on 4 cornerstone foundation supports each situated on the medians of the lanes of intersecting streets and a central support column.
[0015] FIG. 3 illustrates a multi-storey building erected on 8 cornerstone foundation supports situated on the 8 sidewalks adjacent to 8 streets leading to a central octagonal roundabout and a supporting column in the centre of the roundabout
[0016] FIG. 4 illustrates side and top views of a multi-storey parking garage supported by columns erected on the intersection of streets, each street with 3 driving lanes in each direction.
[0017] FIG. 5 illustrates a side view of a multi-storey building built on cornerstone foundation supports situated on the corners of sidewalks and linked by reinforced concrete under the roads. It also illustrates the division of the building between a parking garage, commercial. office and residential floors
[0018] FIG. 6 illustrates the different possibilities of partitioning the floors of the building, by combining a parking garage on the same floor with a residential area, forming residential areas of different sizes with movable flexible partitions or dividing the floor into 8 micro-apartments that are one big living room at day and 3 bedrooms at night.
[0019] FIG. 7 illustrates a top view of a multi-storey residential or office building built on 4 cornerstone foundation supports situated on the 4 sidewalks adjacent to the intersecting streets and four columns situated on the medians of the streets separating the lanes and a support column at the center of the intersection. It also illustrates its division into 8 micro-apartments.
[0020] FIG. 8 illustrates a top view of a residential building erected on 4 column supports situated on the medians of intersecting streets and a column in the center of the intersection.
[0021] FIG. 9 illustrates a multi-storey residential building built on cornerstones on the opposite sidewalks of a 4-lane street.
[0022] FIG. 10 illustrates a 2 storey car garage built on columns situated on the medians of a 4 lane street that can accommodate 80 cars.
[0023] FIG. 11 illustrates a possible furnishing of a micro-apartment using folding furnitures stored in bookshelves-like fixtures that are on rails, that can be moved in parallel to the backwalls and thus form room-like closed spaces.
[0024] FIG. 12 illustrates a driverless autonomous vehicle that facilitates parking in elevated floors of a parking garage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] FIG. 1 illustrates the view from the top of a multi-storey building of 106 feet diameter erected on 4 cornerstone foundation support 1 situated on the 4 sidewalks of the streets intersection and a central support column 3 . The streets have 3 lanes in each direction and 2 of them feature ramps leading to the building, while the 3 rd one enables to pass through under the building and either continue on the same direction or turn right/left or back onto one of the other streets. The traffic under the building may be a free square or controlled by lights.
[0026] Up and down ramps 5 a , 6 a , enable vehicles to reach the first floor of the building from all four directions and from there take the ramps that lead to the upper parking floors.
[0027] The floors of the building rising on the air-space above the intersection, are supported on long-span steel beams 5 a , 5 b supported by the cornerstone columns of minimal cross-sections. The cornerstone columns may be built of steel and concrete and comprise in their structure, elevators 2 including their mechanical and electrical mechanisms that enable to reach all floors from the street level.
[0028] The central section of the building 7 is devoted to up and down ramps for driving cars, while car parking in parking garage floors is reserved on the periphery.
[0029] Access to the floors is through elevators 2 adjacent to the cornerstone columns 1 . Emergency downstairs are located in the middle 4 of each floor.
[0030] The building when used as a parking garage can provide approximately 50 parking places as explained below in connection with FIG. 4 .
[0031] FIG. 2 illustrates a multi-storey building erected on 4 cornerstone foundation supports 21 each situated on the medians of the lanes of intersecting streets and a central support column 3 in the middle of the intersection. In this case, the elevators 22 encompassed in the cornerstone foundation supports, are reached through the pedestrian crosswalks 23 . Consequently triangular barriers 24 are placed in front and behind the cornerstone foundation supports housing the elevators and the paths of the up and down ramps 25 to reach the elevated building, have to be changed circumvent the obstacles.
[0032] FIG. 3 illustrates a multi-storey residential building erected on 8 cornerstone foundation supports situated on the 8 sidewalks adjacent to the 8 streets leading to a central octagonal roundabout, and a supporting column in the centre of said roundabout. Long span beams laid on pairs of cornerstone columns 32 , 33 , 35 may support the octagonal shaped building. Around the central column 3 are emergency downstair escalators 36 , while the elevators 34 adjacent to the cornerstone foundation supports enable access to every floor. Assuming 120′ diameter of the building, each floor has an area of 11,306 sq ft or after deducting the 20′ diameter central area and the area occupied by the elevators an area of 10,672 sq ft.; if divided into 8 residential apartments, this constitutes this comes to 1334 sq ft per apartment.
[0033] FIG. 4 illustrates side and top views of a parking garage floors built on cornerstones 1 , situated on the sidewalks 40 of 4 streets forming an intersection, and a column 3 in the middle of said intersection. In this illustration, the distance between the cornerstone posts on which long-span beams that support the structure are laid, is 80′ and the distance between a cornerstone post and the central column is 57′. In this illustration, each street has 3 driving lanes in each direction; the lanes close to the sidewalk 43 a , 44 a are used to traverse the intersection under the building, while the other 2 lanes in each direction have ramps up to 43 b and down from 44 b the parking garage. The illustrated parking garage building has a diameter of 106′; the central 34′ diameter section 41 has at its center the 6′ wide column that supports the beams holding the structure. Around the central column 3 are 4′ wide downstairs 42 , on a diameter of 14′. Around the stairs are two counter-spiraling, 10′ wide ramps on an outer perimeter of 34′ diameter, that assuming traveling in the middle of the ramp, constitutes a 9% inclination. This leaves for a doughnut shaped parking area 49 , with an outer diameter of 106′ and inner diameter of 34′, although some additional parking area is available on the inner section, between entry and exit sections 51 of the spiraling ramps. Cars may be parked along the outer periphery at 8′ distance by width one from the other 50; taking in account the width of the 4 columns housing the elevators (4×6′) this mode allows 35 parking spots. Parking along the inner area, around the 14′ diameter column housing the stairs, requires leaving 2 exit spaces for the cars entering and exiting the ramps. Parking lengthwise every 8′ around the 34′ diameter periphery, while leaving 2 exit spaces for the cars to enter and exit the ramps, allows 13 additional parking places. This geometry leaves a 16′ wide corridor 53 for maneuvering the parking cars. Thus around 48-50 cars can be parked in every floor.
[0034] The location of the car ramps between the floors might also be different than the one illustrated; for example the up and down ramps may be located on the periphery of the building or one ramp on the periphery and the other on the center of the buildings. Obviously the stairs too may be located on different parts of the floor.
[0035] FIG. 5 illustrates a side view of the multi-storey building standing on cornerstone foundation supports 1 and a central column 3 . To improve the stability of tall buildings, the 4 cornerstone foundation supports may be linked to an under-the-streets platform of steel and concrete 48 .
[0036] The efficiency of the multi-storey building is enhanced by including in the same building, above the parking garage floors, also commercial 50 , office 51 and residential floors 52 , in this order. Thus for example a resident of the upper floors may have an office in one of the office floors beneath the residential floors, attend some of the shops in the commercial floors and have his car parked in the parking garage of the building.
[0037] FIG. 6 illustrates a possible combination of a residential area in a multi-storey building standing on cornerstone foundation supports and a central column as illustrated in FIG. 5 , with a connected parking garage 58 on the same floor. The parking garage adjacent to the residential area has direct access 59 to the up and down ramps 57 and thus saves time, when coming in and going out of the apartment. The remaining total floor area of 6534 sq ft may be divided into 4 residential apartments of 1630 sq ft each or furnished with movable partitions, 55 a , 55 b , 55 c , 55 d on rails 56 that enable flexible living room sizes, depending on the circumstances. The flexible partitions may also serve both as bookshelves and for storage of foldable furniture as explained below in paragraph 14 and illustrated in FIG. 11 .
[0038] The floor area 60 outside the car ramps 57 totaling an area of 8825 sq ft may also be divided into 8 apartments 990 sq. ft each. The apartments may have movable internal partitions 61 a , 61 b on rails that when moved away from the back walls, for example for 10 ft, form 280 sq ft. rooms. The bookshelf like partitions may store foldable beds, chests, tables and chairs, that when unfolded turn these rooms into bedrooms at night.
[0039] FIG. 7 illustrates a top view of a multi-storey residential or office building built on 4 cornerstone foundation supports 1 situated on the 4 sidewalks adjacent to the intersecting streets and four columns 63 a situated on the medians of the streets separating the lanes and a support column 3 at the center of the intersection. The cornerstone rectangular columns also comprise elevators 63 b that can be accessed and exited from 2 directions. The illustrated streets in this case are 60′ wide, narrower than the exemplary 80′ wide streets shown in FIGS. 1 and 2 . In this case having support columns 64 on the medians of streets allows the use of shorter beams to support the building standing in the air-space above the intersection. Nonetheless each floor, in this case may accommodate 8 apartments or offices of approximately 1070 sq ft each. In this architecture, some common appliances like washing and drying machines airconditioning and a network communication server 66 may be shared and located in a common space 65 outside the apartment/office. The building does not comprise parking places. A simple parking garage of two floors is illustrated in FIG. 10 .
[0040] FIG. 8 illustrates a top view of a residential building erected on the air-space supported by 4 column 70 situated on the medians of intersecting streets and a column 72 in the center of the intersection around which are located the emergency downstairs and the water and sewage conduits. In this type of a building, access and exit is through the elevators 71 adjacent to the supports and accessible only through pedestrian crossings 73 . Therefore the medians close to the pedestrian crossings have to be modified so that traffic in the adjacent lanes is moved away from the building supports and the adjacent elevators by proper physical barriers 74 . Such buildings erected on the air-space at intersections of comparatively narrow streets may provide 4 dwellings having an area of 390 sq ft each for each floor.
[0041] FIG. 9 illustrates two multi-storey residential or office buildings erected on the air-space between the opposite sidewalks of a relatively narrow street where on both sides of the street are open spaces such as parks, without residential buildings. Thus such buildings do not hamper the view across the street to anyone.
[0042] One of the buildings is a rectangular 30′ wide structure erected on 3 support columns 77 a , 77 b and 77 c extending for a total span of 60′, on each side of the street. The building is supported by 40′ beams 81 extending from one side of the street to the other. The resulting 40×60=2400 sq ft floor area may be divided into four residences, each 600 sq ft large. Access to each apartment is through an elevator 78 adjacent to the cornerstone columns. Emergency stairs 79 are by the middle support column 77 b that also contain the water and sewage installations 80 .
[0043] The second building has a triangular shape; the base of the triangle is supported by two cornerstone foundation supports 82 a , 82 b on the sidewalk of the street and the apex is supported by a column 82 c in the middle of an intersecting street, 45′ away from the base. The triangular structure is held by long-span steel beams of 50′ long at the base and 50′ long between the base and the apex, laid on the steel reinforced concrete cornerstones, on each floor. Access to the various floors is by elevator 84 adjacent to the cornerstone column 82 a . Emergency escalators 85 from each floor are by the cornerstone column 82 b Each floor has a surface of 900 sq ft.
[0044] This figure also illustrates a pyramide-like structure 86 that may be erected on 3 cornerstone foundation supports 86 a , 86 b , 86 c ; inclined steel beams with one of their ends on the support columns, may be joined at their other ends at the apex of the pyramide 86 d . The pyramid may have a second floor supported at half-beam points by a triangular girdle holding a triangular platform. Access to the second floor 87 may be by stairs 88 affixed to one of the beams.
[0045] FIG. 10 illustrates a 2 storey car garage built on 4 cornerstone foundation support columns 90 on each of the opposite sidewalks of a street 40′ wide. The length of the illustrated parking garage is 120′ and each side may accommodate 15 cars, leaving a 10′ lane in the middle of the two parking rows. Access and descent to the first floor of the parking garage, is through the respective up ramps from one direction 89 a and access and descent from the second floor is through the respective ramps from the other direction 89 b . People descent is through stairs 89 behind the support columns.
[0046] As each floor of the parking garage may accommodate 30 cars, the parking garage may accommodate 60 cars. As the up and down ramps in practice block the two middle lanes of the street, they can also be used for additional parking of another 30 cars.
[0047] FIG. 11 illustrates a possible furnishing of a micro-apartment of 360 sq ft illustrated in FIG. 7 , using folding furnitures stored in bookshelves-like fixtures 92 a , 92 b that are on rails 93 a , 93 b and can be moved in parallel to the backwalls, thus forming room-like closed spaces of 60 sq ft and 70 sq ft. A master folding bed 96 and two chests 97 may unfold out of one of the bookshelf-like fixtures thus forming a master bedroom, while out of the other bookshelf-like fixture two child beds 101 a , 101 b and a desk 100 a may unfold. Out of the other side of the bookshelf-like fixture a couch 100 b and two armchairs 102 a , 102 b may unfold for use in the 120 sq ft living room. Other collapsible furniture stored in the bookshelf-like fixture include a collapsible table 93 and chairs 98 .
[0048] FIG. 12 illustrates the autonomous driverless parking feature that facilitates parking in elevated floors. While driving a floor or two or even three for parking a car is acceptable, driving 10 or 20 floors is not. Therefore autonomous, driverless parking is a must in multi-storey parking garages.
[0049] The status of any parking place, in the multi-storey garage is at all times monitored, for example by light beams between a light source 109 a and a light sensor 109 b , that indicate when the space between the two is blocked. This information is transferred by wireless to a central processor 121 that broadcasts this information on the internet and displays it visually on large displays 104 inside and outside the parking garage.
[0050] As the route 106 in the garage, from the base station where the car driver leaves his car, to a preassigned parking place 108 is well determined, the car may be brought to its parking place by a robotic platform 111 that follows the preassigned route. The robotic platform 111 is on sturdy wheels 126 and gets its instructions by wireless 113 from a central processor 121 through a remote controller which can be a smartphone 122 loaded with a specific application. When placed under the car, its hydraulic car jack like lever 114 may be activated to lift the car that may weigh up to 2 tons.
[0051] The energy E needed to lift the car for 10 floors, for example, taking in account 7′ high parking garage floors, may be calculated by E=mgh where (m) is the weight of the car (2 tons) (g)=9.81 is the gravity constant and (h) height of the 10 floors. This calculation neglects the friction to be overcome while climbing the 10 floors.
[0000] mgh=[2.10 3 (9.81)]·[21 meters]≅(4.2)10 4 Joules=42 kw-second
[0052] In terms of LiFePo 4 battery capacity that produces a voltage of 3.2V, in (Amp)(hour) terms, 1 Ah, (3.2) (3600)watt-sec=11.5 kW·sec.
[0053] Therefore the energy needed to move a 2 ton car for 10 floors is [(42)/(11.5)]=3.65 Ah
[0054] An order of magnitude estimate for all other factors that consume energy, mainly friction and motor inefficiencies, may be obtained by comparison with the energy consumption of electric cars. An electric car uses on the average around 25 kWh for 100 miles. The length of the 10 floors route in the parking garage described in FIG. 3 is 10(πD)=1068′; adding a tour of the floor of πD=333′ for parking the car and multiplying by 2 for the return trip, it comes to a total route of 2800′ which is approximately ½ th of a mile.
[0055] Therefore it approximately takes for an electric car less than 125 Wh or 40 Ah of LiFePo 4 batteries with a V=3.2V to run the 0.5 mile route. Adding to that the energy to lift the car of 3.65 Ah the total energy expended comes to approximately 44 Ah.
[0056] Thus a battery of 220 Ah having dimensions of 205*103*370 mm can support more than 5 parking tours up and down up to 10 floors, before requiring a recharge.
[0057] The robotic platform may travel at 10 miles/hr taking 3 minutes to travel the parking route of 1400′ forth and back. Future Lithium Sulfure batteries that promise to have 4 times the capacity for the same energy will enable to reduce the size of the batteries in the trolley. The trolley uses more than 90% efficient DC motors 123 that determine speed, to control each of the 4 wheels 126 independently, thus enabling to steer and maneuver itself into narrow parking spaces accurately.
[0058] The wheels' axial positions are independently controlled by other electrical motors 125 that also receive their instructions by wireless from the central processor 121 through a controller that may be a smartphone. Thus for example when all 4 wheels are turned onto a direction perpendicular to the long axis of the platform 127 , the trolley will move sideways, for example onto a parking place 128 by the sidewalk of the road.
[0059] The robotic platform carries a magnetic sensor 117 that senses deviation from a magnetic strip or wire laid on the middle of the ramps and the routes to the parking places in all the floors. Alternatively other technologies may be used to sense the middle of the route, for example a camera for detecting the position of a specific colored strip.
[0060] The route of the trolley may also be controlled by an inertial guidance system. Using MEMS sensors to measure velocity, accelerations and pressure as a function of time, enable to determine current position at all times and lead the trolley to the allocated parking place of the car.
[0061] When following a track, the deviation signal from the center of the track is processed and an appropriate correction signal is fed to the DC motors that control the 4 wheels, thus enabling to stay on course, reach the parking place and park the car. The robotic trolley may then lower the car onto its wheels and wait for further instructions. A video camera and an ultrasound emitter-sensor for distance measurement 112 is placed on top of the car for imaging the route to the parking place and watching any unforeseen situation from a control center manned by a human. The human controller can at all times stop the robotic platform and or assign it a route different than following the magnetic/colored strip, by giving its DC motors that control the routes the appropriate directions.
[0062] An optical camera with an ultrasound emitter/sensor 108 E positioned on the car roof transmit images at all times during the route to the parking place. The ultrasound emitter/sensor measures distance from reflectors 108 U pre-installed in the multi-storey garage at strategic places, for example at an exit of the ramp, and enable to transmit distances from such reflectors thus complementing the visual images.
[0063] There are multiple ways to realize the invention explained above, combine the differentiating features illustrated in the accompanying figures, and devise new embodiments of the method described, without departing from the scope and spirit of the present invention. Those skilled in the art will recognize that other embodiments and modifications are possible. While the invention has been described with respect to the preferred embodiments thereof, it will be understood by those skilled in the art that changes may be made in the above structures and in the foregoing sequences of operation without departing substantially from the scope and spirit of the invention. All such changes, combinations, modifications and variations are intended to be included herein within the scope of the present invention, as defined by the claims. It is accordingly intended that all matter contained in the above description or shown in the accompanying figures be interpreted as illustrative rather than in a limiting sense.
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The invention discloses multi-storey building structures of different sizes and purposes, built on long-span beams laid on cornerstones of minimal dimensions, on the opposite sidewalks of streets and the medians separating street lanes. Such buildings basically occupy the air-space above streets and roads and may be used for parking garages, residential, office and commercial space or for an optimal combination of them. Parking garages built on the air-space above intersections of roads may enable entry from any direction and exit to a different one, with or without parking and greatly contribute to the rationalization of car traffic in modern mega-cities. Such multi-storey buildings comprising in addition to parking garages, office, residential and commercial space, may save valuable timing wasted in going from one place to another.
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RELATED APPLICATIONS
[0001] A Provisional Application was submitted on Jun. 2 nd , 2002, with a granted filing dated given of Jun, 4, 2002, by the United States Patent and Trademark Office, confirmation number 6794 under application No. 60/385,951.
BACKGROUND OF THE INVENTION
[0002] This invention relates to an improvement to the External Insulation And Finish System (EIFS), especially the non-combustible variation to the External Insulated And Finish System, which is mandated, when a non-combustible high impact resistant wall panel is required per municipal building code or architect preference, especially in hurricane or tornado areas of the United States.
[0003] EIFS, which is a type of cladding for exterior building walls, is defined per ASTM E631-91b as a “a non-loading outdoor wall finish system consisting of a thermal insulation board, an attachment system, a reinforced base coat, exterior joint sealant, and a compatible finish”.
[0004] The development of EIFS occurred after World War II and was introduced to North America in the late 1960s or early 1970s as an EIFS called Dryvit™. While there are slight differences in the EIFS between the European and North American methods for the “System”, there are mandatory components for the EIFS wall cladding in both cases.
[0005] As described in detain later herein, the mandatory components of a typical prior art EIFS (see FIG. 1), are: a stud 3 and sheathing substrate system 4 , which the EIFS is attached, such as wood sheathing, mineral boards, an exterior grade or glass fiber-faced gypsum board, or cement board insulation made of expandable polystyrene 6 ; attachment means for attaching the insulation to the substrate; a base coat adhesive 7 with reinforcing mesh 8 embedded in the adhesive located over the outside face of the EPS insulation board; and the finish 9 , which is basically an esthetic part of the EIFS and is the visible portion of the wall system. This finish coat is typically made from an acrylic resin, which is either troweled or sprayed on, and a joint sealant system of which there are several types. Items 7, 8 and 9 are collectively referred to as the EIFS' “lamina”.
[0006] The EIFS cladding is typically comprised of at least those components as described above. Each component has its own specification(s) with several manufacturers supplying any one component. A critical component of the system is the Expandable Polystyrene (EPS) insulation board. Expandable Polystyrene comes to the molding facility looking very much like a grain of sand, with a weight per cubic foot of about 64 pounds. The polystyrene beads included a thin outer layer of polystyrene and a hollow interior that includes a blowing agent, such as pentane. In pre-expanding, the beads are expanded by applying heat through hot air or steam, which causes the blowing agent to vaporize and expand the bead, to the desired density required for the second step, which is to mold the beads, through heat, steam, pressure and cooling, into the desired construct, for example; a panel, packaging material or helmet. Each construct has its own desired density requirements. In the EIFS industry the EPS beads are pre-expanded to its desired weight, which is from 0.9 to 1.1 pound(s) per cubic foot. This weight is about at the lowest limit EPS it can be pre-expanded to and molded.
[0007] In the EIFS industry this EPS board is required to have very specific characteristics, such as, it can be no less than ¾ of an inch thick, nor more than 4 inches thick, and needs to be pre-expanded to and molded at a density of one pound per cubic foot, plus or minus ten percent. EPS at one-pound density acts as a buffer or type of “shock” absorber, between the substrate and the “lamina”, which is the base coat, mesh and finish or esthetic coat, as described as items 7, 8, and 9 above. The ability of the EPS to flex as the substrate moves, or the lamina expand and contracts, allows the EPS to absorb the energy of a shearing movement and to minimize the energy or stop the shearing energy from passing through the EPS to the lamina, which could cause it to crack and/or deform. EPS at a density of more than 1 pound per cubic foot is stiffer and has been found to not give the EPS board the elasticity, which helps to prevent deforming or cracking in the lamina. Accordingly, with EPS board made at higher densities the greater the tendency to transfer any build up of forces from the substrate to the lamina, that might otherwise cause deforming or cracking. In fact, EIFS manufacturers will not warrant their systems if the EPS insulation board is of the wrong density. By not using EPS and by instead applying the lamina directly to a substrate, any build up of forces in the substrate may be passed directly through it and could cause cracking in the lamina. The above describes the components, which are the integral parts of the External Insulated and Finish System (EIFS), and outlines why the EPS panels have a requirement by the EIFS manufacturers that the EPS board by made at 0.9 to 1-pound density.
[0008] It is known in the art that the EIFS cladding, when used in hurricane or tornado parts of the United States, are modified to include at least two more layers of mesh, in order to withstand the high impact of a foreign object as might occur during a hurricane or tornado. As later described in detail, FIG. 2 depicts a prior art cladding construct modified to withstand heavy impacts. These extra layers of mesh are required because EPS at one-pound density while flexible, is very fragile and can be crushed or punctured rather easily, when it is made with the industry standard base coat, fiberglass mesh and finish material, as depicted in FIG. 1 and noted as numbers 7,8 and 9. Building codes, such as those in Miami-Dade County Florida, have adopted a Hurricane Protocol. A component of the testing protocol is PA 201, the “Large Missile Impact Test”, which is becoming the standard for building codes in hurricane and tornado regions of this country. There are several elements to the testing protocol, but of major concern in the EIFS industry is passing the large missile impact test. In this test, a 2×4 wood framing stud, about 9 feet long, is propelled from a “canon” at a speed of about 42 miles an hour at the surface of the object that is to be tested. The missile must not penetrate through the object tested to the inside of said object, or a test failure will occur. In the case of a wall panel, the missile must not crack or puncture the substrate so that light may be visible from the inside of the exterior wall cavity to an outside light source.
[0009] Improvements in the construction, with substantial cost savings of the above described External Insulated and Finish System, EIFS, are provided in accordance with this invention to achieve the same high impact non-combustible resistant panel system by providing a panel construct where the use of a high density expandable polystyrene panel, as is described in the teaching by Cutler in U.S. Pat. No. 5,718,968, is used in place of a layer of heavy weight fiberglass mesh. By using a high density EPS panel in place of a layer of fiberglass mesh, a savings in time and cost is achieved by doing away with the cost of the fiberglass mesh, the application of the adhesive, and the time and labor involved with embedding the fiberglass into the adhesive, with the attendant “down time” because of the need to allow the adhesive to dry and “set up”.
[0010] By simply attaching, through screwing, gluing or nailing, the high density panel to the stud or its backing, a rather inexpensive alternative to the prior art EIFS has been accomplished. This high density panel at about 2 foot by 4 foot in dimension can be attached simply and quickly, especially when working on scaffolding many floors off of the ground since it is reasonably light in weight yet offers the impact resistance that is currently required in the EIFS construct by building codes in certain hurricane and tornado areas of the country.
[0011] The present invention provides an exceptionally strong non-combustible Expandable Polystyrene And Fixed System construct at a substantial cost savings over typical EIFS prior art systems, as are outlined in FIGS. 1 and 2.
[0012] Saving is achieved without sacrifice in impact resistance by employing a high density Expandable Polystyrene (EPS) panel/board in place of a layer of high impact reinforcing as shown in FIG. 3, a single layer of high impact reinforcing mesh is then attached to the high density board, and then a layer of conventional 1-pound EPS board with a light weight mesh embedded in an adhesive; a finish material, such as a stucco material or acrylic based finish coat, is then applied.
[0013] In accordance with the foregoing objective, a high impact resistant EIFS construct is achieved by using the high density EPS panel in lieu of a layer of fiberglass mesh, having the advantage of a time saving method with low cost, and ease of construction, over the standard EIFS claddings as are furnished by the various EIFS manufacturers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a Cross-Sectional drawing of an EIFS construct according to the prior art, as is typically used in the industry.
[0015] [0015]FIG. 2 is a Cross-Sectional drawing of an EIFS construct according to the prior art, as is typically used when a non-combustible high impact EIFS system is required, either by building code or architect preference.
[0016] [0016]FIG. 3 is a Cross-Sectional drawing of an EIFS construct provided in accordance with the present invention.
DETAILED DESCRIPTION
[0017] Prior Art
[0018] An EIFS construct can be formed by the conventional EIFS method of applying the mandatory components as shown in FIG. 1. These are: A substrate system 4 (the surface to which the EIFS is attached), such as wood sheathing, mineral boards, exterior grade or glass fiber-faced gypsum board, or cement boards, which is attached to a wood or metal framing stud 3 ; Insulation board 6 , which shall be by steam expansion of polystyrene resin beads, to a minimum weight of 0.9 to 1.1 pounds per cubic foot, and at a thickness of at least ¾ of an inch 6; Attachment systems: base coat 5 A for attaching the insulation to the substrate, the attachment base coat adhesive, such as that used by the Dryvit Systems, Inc of West Warwick Rhode Island, consisting of a “Primus” mixed by weight with Portland Cement and water based primus, which is a 100 percent polymer based product, or 5 B, a mechanical fastener, such as a screw or nail. To the base coat adhesive 7 is embedded, over the outside face of the EPS insulation board 6 , for example, a Dryvit standard plus reinforcing mesh 8 , typically of a weight between 4 to 5 ounces per square yard. The finish coating 9 is basically an esthetic part of the EIFS, which is the visible portion of the wall system, and is typically made from an acrylic resin, or stucco product, which is either troweled or sprayed on.
[0019] To the mandatory components of the construct as shown in FIG. 1 are added layers of reinforcing mesh, as shown in FIG. 2, which are used when an EIFS is required to pass certain building codes, in for example hurricane and tornado areas of the country. The first layer of reinforcing mesh 7 is typically made of a glass woven fiber, with a weight of between 6 to 11 ounces per square yard. It is adhered to the substrate 4 with a base coat 5 consisting typically of Portland Cement with a setting additive, which is typically a 100 percent polymer based product. To this layer is added the EPS 9 by an attachment system 6 A or 6 B, of either a mechanical means or an adhesive, which is typically a 100 percent polymer based product mix, which may be mixed with an 100 percent acrylic based product and with water and Portland Cement. To the outside of the installed EPS board 9 is embedded, into a base coat 10 a very heavy high impact fiberglass reinforcing mesh 11 , typically of a weight of between 15 to 22 ounces per square yard. Added to this layer of mesh is the standard base coat and reinforcing mesh 12 , which is typically of between 4 to 6 ounces per square yard in weight. To this last layer is added the finish coat 13 , which is mainly used for esthetic purposes and consists typically of a 100 percent acrylic based product. The added layers 7 & 11 , of the heavy weight high impact reinforcing mesh are the integral components to the standard EIFS construct, and are a requirement in order to pass the Hurricane Testing Protocol, especially the Large Scale Missile Impact, PA 201 as is required in the Miami-Dade County South Florida Building Code.
[0020] The Present Invention
[0021] The present invention does away with one of the required layers of mesh and its attachment system that are shown in FIG. 2. FIG. 3 illustrates a construct according to the present invention. This variation to the EIFS System in its use of a high density EPS board 6 in place of the high impact fiberglass layer 7 , as described above, and as depicted in FIG. 2.
[0022] Koch's 1955 U.S. Pat. No. 3,445,406 discussed the making of a high-density Expandable Polystyrene, EPS board. A refined process for producing a high-density EPS board is outlined by Cutler in his 1998 U.S. Pat. No. 5,718,968. In it he describes the making of a high-density EPS construct through a two-step molding process. Cutler uses a compression molding technique or process, which “gives” the construct more of an energy-absorbing “memory”, and structural strength, without an increase in embrittlement, than what could be offered by a regularly molded high-density board. The “memory” allows for the board to withstand higher impacts, that is, when impacted the construct does not deform to the degree a regularly molded high-density construct would. In this invention a high-density board, with a density of between 11 pounds per cubic foot and 15 pounds per cubic foot is used. In regular EPS molding an EPS construct can be made up to densities of about 8 pounds per cubic foot. Regular EPS molding at such high densities is difficult and at times leaves the molded construct brittle, which is not the case when a construct is made per the process as described by Cutler. The present invention employs that process to produce the unique component of the present invention, the EPS board identified by reference numeral 6 in FIG. 3.
[0023] In the present invention as shown in FIG. 3 a newly developed non-combustible EIFS construct is detailed. This non-combustible EIFS construct is attached to a suitable wall stud, typically a land ⅝ inch, at least, 16 gauge, metal stud 3 , spaced at about 16 inch on centers. The construct includes a substrate of at least ¼ inch exterior or water proof grade gypsum board or other “non-combustible” sheathing material 4 , which is attached either by an adhesive, screws or nails to the metal stud 3 . To the sheathing substrate is attached, either through nailing, screwing 5 A or an adhesive 5 B or a combination thereof, the high density board 6 . To the high-density board 6 is affixed a layer of high impact reinforcing fiberglass mesh 7 of at least about 11 ounces per square yard to about 20 ounces per square yard, which is embedded in a standard base coat 8 of Portland Cement and an adhesive additive, which is typically a 100 percent polymer based product. To the high impact reinforcing fiberglass mesh 7 is attached an Expandable Polystyrene (EPS) board 9 of at least ¾ inch thick with a density from between 0.9 to 1.1 pound per cubic foot. The EPS board is affixed by the use of an adhesive base coat 10 A or mechanical means, such as with nails or screws 10 B. Attached to the outside portion of the EPS is a standard reinforcing mesh 11 of about 4 to 5 ounces per square yard, which is embedded into a standard base coat 12 and adhesive, as is typically used in the industry. To this last layer is added the finish coat 13 , which is mainly used for esthetic purposes and consists typically of a 100 percent acrylic based product.
[0024] While I have described a preferred embodiment of my invention as having the various layers in a certain order, it will be apparent to those skilled in the art that other orders may be employed. For example, the high impact mesh 7 may be the layer immediately adjacent the substrate 4 , or it may be the layer immediately adjacent the mesh 11 . Moreover, in some cases, it may not be necessary to include the substrate at all. The important aspect of the invention is the inclusion of both the high-density board 6 and the lower density board 9 in the construct.
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An External Insulated And Fixed System (EIFS) and method for making the same. The method provides a cost effective procedure for constructing an EIFS that can meet current hurricane high impact test protocol, especially for non-combustible EIFS “Systems”. A reinforcing high impact layer of fiber glass mesh is eliminated, and a high density compression molded expandable polystyrene board is provided that yields significantly improved impact resistance
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[0001] This application claims priority from Chinese Patent Application No. 201110197353.1 titled “SOLAR THERMAL POWER GENERATION SYSTEM AND THERMOELECTRIC CONVERSION DEVICE THEREOF”, filed with the Chinese State Intellectual Property Office on Jul. 14, 2011, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present application relates to the technical field of solar thermal power generation, and particularly to a thermoelectric conversion device for a solar thermal power generation system. In addition, the present application further relates to a solar thermal power generation system including the above thermoelectric conversion device.
BACKGROUND OF THE INVENTION
[0003] Solar energy is one of the new energies that are most promising and most likely to meet continually increased demand for energy in future social development, and has characteristics such as unlimited reserves, wide distribution, clean utilization and the economical efficiency. The solar thermal power generation has some characteristics, for example, better adaptability to power grid load, high photoelectric conversion efficiency, scale effect with ease, environment-friendly manufacturing process of consumptive material, better adjustability of the electric power, and so on. Thus, the solar thermal power generation is an important development direction of utilization of solar power generation in the future.
[0004] The basic technical idea of the solar thermal power generation is that: the sunlight is converged through a heat collector to increase the energy density of light energy; the collected light energy is absorbed by a heat absorbing device and converted into heat energy; the heat energy is transferred to working medium to increase the internal energy of the working medium; and then the internal energy in the working medium is converted into mechanical energy through a heat engine and a generator is driven so that the mechanical energy is further converted into electric energy to be output. In the whole process of energy conversion, converting the heat energy into the mechanical energy is the most critical aspect.
[0005] Currently, there are mainly three kinds of the heat engine that are applicable to the solar thermal power generation system, i.e., the steam turbine based on Rankine cycle, the Stirling engine based on Stirling cycle and the small-scale gas turbine based on Brayton cycle. Specifically, the steam turbine can use hydrocarbons (halogenated hydrocarbons) or water having low boiling point and good heat stability as the working medium. However, because the temperature that the working medium can withstand is low, the heat efficiency is low. The steam turbine is generally used in a slot-type power generation system with low the heat collection temperature. The Stirling engine uses hydrogen or helium working medium which has the dynamic seal pressure up to 15 Mp or more when working, so that the working reliability, stability and lifetime is limited to some extent. The small-scale gas turbine can directly use air as the working medium. That is, air is compressed by a compressor, then absorbs heat and is heated up in a working medium heating device, and then goes into a turbine for expanding and doing work; and the mechanical work in turn drives the compressor and the generator for outputting current. The small-scale gas turbine is simple in the design, has no demanding seal conditions, directly obtains and discharges the working medium from and into atmosphere, and has better reliability and stability.
[0006] However, for using the small-scale gas turbine as the heat engine for solar thermal power generation equipment, there are following several problems to overcome in addition to difficulty in designing impellers of the compressor and the turbine with high efficiency as well as high speed generator:
[0007] 1) start-up performance of the system: because the turbine and the compressor are coupled to each other, after the compressor drives the high-pressure airflow into the heat collector, the heat generated by the heat collector can be absorbed by the airflow, and the formed high-temperature and high-pressure airflow can pass through the turbine to output mechanical work and to drive the compressor and the generator. Thus, when the system is actuated, an additional starting device is required to give an initial rotating speed to the compressor. In this way, the whole system can be actuated smoothly, resulting in a more complex structure of the thermoelectric conversion device.
[0008] 2) lifetime and reliability of the high speed generator: because the operating rotating speed of the small-scale gas turbine is up to 100000 to 200000 r/min, cooling requirement of the generator is extremely demanding. It is necessary to provide a good solution to cooling, otherwise the lifetime and reliability of the generator will be affected.
[0009] 3) operation stability and robustness of the system: when the high-temperature air going into the turbine air inlet deviates from the designed working temperature and pressure of the turbine due to fluctuation in solar radiation and so on, the rotating speed of the turbine impeller will significantly fluctuate, resulting in a fluctuation in the rotating speed of the turbine impeller, and the flow and pressure of the air going into the working medium heating device will fluctuate as well, thus further leading to fluctuation in the rotating speed of the turbine impeller, and causing loss of stability of the system.
SUMMARY OF THE INVENTION
[0010] A technical problem to be solved according to the present application is to provide a thermoelectric conversion device for a solar thermal power generation system, which has a better startability since there is no need for additionally providing a start-up device to rotate a compressor when the thermoelectric conversion device is started, and has a better stability since the generator can be better cooled in the process of thermoelectric conversion. Another technical problem to be solved according to the present application is to provide a solar thermal power generation system including the thermoelectric conversion device.
[0011] In order to solve the above technical problems, there is provided according to the present application a thermoelectric conversion device for a solar thermal power generation system including a generator, a compressor, a turbine and an intermediate body fixedly connected between the compressor and the turbine. A transmission shaft is rotatably connected inside the intermediate body. The transmission shaft is fixedly connected to a rotating shaft of the generator, and a compressor impeller of the compressor and a turbine impeller of the turbine both are mounted on the transmission shaft. The generator is further connected to a lead for inputting current. When the system is started, the generator functions as an electric motor; and when the system is in normal operation, the generator functions to produce electricity.
[0012] Preferably, the generator is arranged in an air inlet flowing passage inside the compressor.
[0013] Preferably, a heat insulation plate is provided between a rear flange of the intermediate body and a turbine volute of the turbine, and an annular nozzle is formed between the heat insulation plate and a vertical rear side wall of the turbine volute.
[0014] Preferably, at least one airflow guide vane for adjusting the injection-expansion ratio of airflow within the nozzle is provided in the nozzle.
[0015] Preferably, the heat insulation plate is provided therein with a through hole oriented in the fore-and-aft direction. An outer end of the airflow guide vane is pivotally connected in the through hole, and an inner end of the airflow guide vane swings as the outer end rotates in the through hole.
[0016] Preferably, a rear side wall of the intermediate body is provided with an arc-shaped hole, and a shift lever slidable along the arc of the arc-shaped hole is inserted into the arc-shaped hole. The shift lever extends through a rear end of the intermediate body to be connected to a slide ball that rotates in an end surface along with the shift lever. A shift fork is provided in front of the heat insulation plate. The outer end of the airflow guide vane is fixedly connected between two fork-shaped portions of the shift fork, and a straight-bar portion of the shift fork is slidably inserted into a through hole in the slide ball.
[0017] Preferably, a diffusing pipe of the compressor is an annular space formed between an end surface of a positioning boss on the front flange of the intermediate body and a corresponding portion of a compressor volute.
[0018] Preferably, the intermediate body is rotatably connected to the transmission shaft through a floating bearing, and a thrust bearing is provided in front of the floating bearing. An oil inlet hole is provided at the top end of the intermediate body. Lubrication passages leading to two of the floating bearing and the thrust bearing are provided at the bottom end of the oil inlet hole. An oil outlet hole is further provided at the bottom end of the intermediate body. An oil baffle plate is further provided at a lower end of a transition ring located in front of the thrust bearing, and the oil baffle plate is arranged to be inclined towards the oil outlet hole.
[0019] Preferably, a sealing element is provided at contacting area between a front end of the transition ring and a bearing cover of the thrust bearing, and an oil throwing plate that projects towards the outside of the transmission shaft is further provided on the transition ring between the sealing element and the oil baffle plate.
[0020] Preferably, a projecting ring is provided at the rear side of the rear floating bearing of the transmission shaft, the sealing element is provided at a contacting area between a rear end of the projecting ring and a side wall of the intermediate body.
[0021] In the thermoelectric conversion device for a solar thermal power generation system according to the present application, a transmission shaft is rotatably connected inside the intermediate body; the transmission shaft is fixedly connected to a rotating shaft of the generator, and a compressor impeller of the compressor and a turbine impeller of the turbine both are mounted on the transmission shaft; the generator is further connected to a lead for inputting current; when the system is started, the generator functions as an electric motor; and when the system is in normal operation, the generator functions to produce electricity.
[0022] By employing the thermoelectric conversion device with this structural form, when the system is started, external current is input to the generator through the lead so as to drive the rotating shaft of the generator to rotate. At this time, the generator is used as an electric motor, and drives the compressor impeller to rotate. Under the action of the compressor impeller, air coming from the atmospheric environment enters through a compressor entrance and flows through an air flowing passage into compressor impeller. The air obtains energy in a vane flowing passage of the compressor impeller to increase the flowing speed, temperature and pressure thereof. Then the air goes into a diffusing pipe and reduces flowing speed in the diffusing pipe, but further increase the temperature and pressure thereof, thus forming high-pressure air which is output through a compressor volute and a compressor air outlet. The high-pressure air described above goes into a heat exchanger through a pipe with a heat insulation layer, and then flows into a working medium heating device where the air is heated at constant pressure so as to form high-temperature air. The high-temperature air goes into turbine volute through a turbine air inlet and then flows through a nozzle. In the nozzle, the high-temperature air expands so as to achieve pressure reduction, temperature reduction and speed increase, and thus part of pressure energy is converted into kinetic energy. A high-speed airflow flowing out from the nozzle impacts a turbine impeller, and further expands and does work in a flowing passage of the turbine impeller, so as to achieve pressure reduction, temperature reduction and speed increase and push the turbine impeller to rotate. Finally, the air is discharged through an exhaust pipe of the turbine, thus forming the air after doing work. The air after doing work goes into a heat exchanger through a pipe with a heat insulation layer. The remaining heat in the heat exchanger is transferred to the air coming from the compressor, so as to recover part of the energy therein. Thus, the whole cyclic process is completed.
[0023] As the generator functioning as an electric motor causes increase of the rotating speed of the compressor impeller, the power output from the turbine is increasingly large, and the driving power required to be output by the generator is increasingly small, until the power output from the turbine exceeds the power required for the compressor. At this time, the function of the generator is changed from an electric motor to a generator and starts to output electric energy.
[0024] As can be seen from the above working process, in the thermoelectric conversion device with the above structure, in addition to outputting electric energy, the generator functions as an electric motor so as to drive the compressor to rotate at an initial stage of system startup, thereby converting the normal-temperature air into the high-temperature and high-pressure airflow. As compared with the prior art, since there is no need for additionally providing start-up equipment to rotate the compressor, the thermoelectric conversion device according to the application has good startability, so that the thermoelectric conversion device can have simple and compact structure, relatively reduced contour dimension and smaller occupying space.
[0025] The present application also provides a solar thermal power generation system, which includes a heat collector and the above thermoelectric conversion device. The thermoelectric conversion device is provided at an output end of the heat collector.
[0026] Because the thermoelectric conversion device has the above technical effects, the solar thermal power generation system including the thermoelectric conversion device also has the corresponding technical effects, which will not be described in detailed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a partially structural sectional view of a specific embodiment of a thermoelectric conversion device according to the present application;
[0028] FIG. 2 is an overall outline view of a solar thermal power generation system including the thermoelectric conversion device of FIG. 1 ;
[0029] FIG. 3 is a sectional view taken along line A-A in FIG. 1 ;
[0030] FIG. 4 is a sectional view taken along line B-B in FIG. 1 ;
[0031] FIG. 5 is a partial enlarged view of part III in FIG. 4 ;
[0032] FIG. 6 is a partial enlarged view of part II in FIG. 1 ;
[0033] FIG. 7 is a sectional view taken along line C-C in FIG. 6 ;
[0034] FIG. 8 is a view seeing from the direction F in FIG. 1 ;
[0035] FIG. 9 is a partial enlarged view of part I in FIG. 1 ;
[0036] FIG. 10 is a longitudinal sectional schematic view of an intermediate body.
[0037] In FIGS. 1 to 10 , the correspondences between the reference numerals and the component names are listed as follows:
[0000]
1-air filtering assembly
2-motor supporter
3-lead
4-air inlet flowing passage
5-generator
6-air inlet pipe
7-compressor impeller
8-compressor volute
9-compressor air outlet
10-high-pressure air
11-front flange
12-intermediate body
13-oil inlet hole
14-lubricating oil
15-shift lever
16-nozzle
17-turbine volute
18-turbine impeller
19-exhaust pipe
20-air after doing work
21-fastening bolt
22-turbine air inlet
23-high-temperature air
24-rear flange
25-oil outlet hole
26-oil baffle plate
27-diffusing pipe
28-transmission shaft
29-tightening nut
30-bearing assembly
31-air deflector
32-normal-temperature air
33-retaining ring
34-seal assembly
35-thrust bearing
36-lubrication passage
37-floating bearing
38-thrust ring
39-transition ring
40-oil throwing plate
41-bearing cover
42-slide ball
43-major clamp piece
44-fastening assembly
45-retaining ring
46-heat insulation plate
47-minor clamp piece
48-shift fork
49-airflow guide vane
50-rotating shaft
51-pin assembly
52-retaining sleeve
53-arc-shaped hole
54-positioning and clamping ring
55-bearing seat hole
56-positioning boss
57-heat exchanger
58-working medium heating device
DETAILED DESCRIPTION OF THE INVENTION
[0038] An object of the present application is to provide a thermoelectric conversion device for a solar thermal power generation system. The thermoelectric conversion device is actuated without additional start-up device for driving a compressor to rotate, thus having good startability, and has an advantage of better stability since the generator can be better cooled in the process of thermoelectric conversion. Another object of the present application is to provide a solar thermal power generation system including the thermoelectric conversion device.
[0039] In order that the person skilled in the art can better understand technical solutions of the present application, the present application will be further described in detail in conjunction with the accompanying drawings and the embodiments hereinafter.
[0040] Referring to FIGS. 1 and 2 , FIG. 1 is a partially structural sectional view of a specific embodiment of a thermoelectric conversion device according to the present application, and FIG. 2 is an overall outline view of a solar thermal power generation system including the thermoelectric conversion device of FIG. 1 .
[0041] In one specific embodiment, as shown in FIGS. 1 and 2 , the thermoelectric conversion device according to the present application mainly include a compressor, an intermediate body 12 , a turbine, a heat exchanger 57 , a working medium heating device 58 and a generator 5 . The compressor is a component that does work to the normal-temperature air 32 by using vanes rotating at high speed so as to increase the pressure of the air. The turbine is an engine that generates power by using fluid impact to rotate an impeller. The intermediate body 12 is an intermediate component that connects the compressor and the turbine. Specifically, a front flange 11 and a rear flange 24 of the intermediate body 12 are fixedly connected to the compressor and the turbine respectively, and a transmission shaft 28 is rotatably connected inside the intermediate body 12 . The transmission shaft 28 is fixedly connected with a rotating shaft of the generator 5 , and a compressor impeller 7 and a turbine impeller 18 both are mounted on the transmission shaft 28 . The generator 5 is further connected with a lead 3 for inputting current. When the system is started, the generator 5 functions as an electric motor; and when the system is in normal operation, the generator 5 functions as a generator.
[0042] By employing a thermoelectric conversion device in such a structural form, when the system is started, external current is input to the generator 5 through the lead 3 so as to drive the rotating shaft of the generator 5 to rotate. At this time, the generator 5 is used as an electric motor, and drives the compressor impeller 7 to rotate. Under the action of the compressor impeller 7 , air coming from the atmospheric environment enters through a compressor entrance and flows through an air flowing passage into compressor impeller 7 . The air obtains energy in a vane flowing passage of the compressor impeller 7 to increase the flowing speed, temperature and pressure thereof. Then the air goes into a diffusing pipe 27 and reduces flowing speed in the diffusing pipe 27 , but further increase the temperature and pressure thereof, thus forming high-pressure air 10 which is output through a compressor volute 8 and a compressor air outlet 9 . The high-pressure air 10 described above goes into a heat exchanger 57 through a pipe with a heat insulation layer, and then flows into a working medium heating device 58 where the air is heated at constant pressure so as to form high-temperature air 23 . The high-temperature air 23 goes into turbine volute 17 through a turbine air inlet 22 and then flows through a nozzle 16 . In the nozzle 16 , the high-temperature air 23 expands so as to achieve pressure reduction, temperature reduction and speed increase, and thus part of pressure energy is converted into kinetic energy. A high-speed airflow flowing out from the nozzle 16 impacts a turbine impeller 18 , and further expands and does work in a flowing passage of the turbine impeller 18 , so as to achieve pressure reduction, temperature reduction and speed increase and push the turbine impeller 18 to rotate. Finally, the air is discharged through an exhaust pipe 19 of the turbine, thus forming the air after doing work 20 . The air after doing work 20 goes into a heat exchanger 57 through a pipe with a heat insulation layer. The remaining heat in the heat exchanger 57 is transferred to the air coming from the compressor, so as to recover part of the energy therein. Thus, the whole cyclic process is completed.
[0043] As the generator 5 functioning as an electric motor causes increase of the rotating speed of the compressor impeller 7 , the power output from the turbine is increasingly large, and the driving power required to be output by the generator 5 is increasingly small, until the power output from the turbine exceeds the power required for the compressor. At this time, the function of the generator 5 is changed from an electric motor to a generator and starts to output electric energy.
[0044] As can be seen from the above working process, in the thermoelectric conversion device with the above structure, in addition to outputting electric energy, the generator 5 functions as an electric motor so as to drive the compressor to rotate at an initial stage of system startup, thereby converting the normal-temperature air 32 into the high-temperature and high-pressure airflow. As compared with the prior art, since there is no need for additionally providing start-up equipment to rotate the compressor, the thermoelectric conversion device according to the application has good startability, so that the thermoelectric conversion device can have simple and compact structure, relatively reduced contour dimension and smaller occupying space.
[0045] It should be noted that the specific mounting position of the generator 5 is not limited in the above specific embodiment. Any thermoelectric conversion device with the generator 5 provided with the lead 3 for inputting current and also functioning as start-up equipment is deemed to fall into the protection scope of the present application.
[0046] In addition, the orientation word “rear” as used herein refers to the flowing direction of the normal-temperature gas after entering through the compressor entrance, that is, the direction from left to right in FIG. 1 . The orientation word “front” is contrary to the above direction, that is, the direction from right to left in FIG. 1 . It should be appreciated that these orientation words are defined on the basis of the accompanying drawings, and the presence thereof should not affect the scope of protection of the present application.
[0047] It is possible to further define the mounting position of the generator 5 described above.
[0048] In another specific embodiment, as shown in FIG. 1 , the above generator 5 can be arranged in an air inlet flowing passage 4 inside the compressor. By employing such a structure, when the unit is in normal operation, part of the normal-temperature air 32 flows through between cooling fins of the generator 5 and compulsorily cools the generator 5 , so that the operating temperature of the generator 5 is maintained within reasonable range, thus ensuring the service time of the generator 5 . As compared with the prior art, the present application can better solve the cooling problem while also saving electric energy consumption on cooling, with no need for additionally providing an electrically driven cooling fan.
[0049] In a specific solution, as shown in FIG. 3 , it is a sectional view taken along line A-A in FIG. 1 . A motor supporter 2 can be provided inside the air inlet pipe 6 of the compressor. An air deflector 31 can also be provided on the air inlet side of the motor supporter 2 , and a bearing assembly 30 can be provided inside the air deflector 31 . The bearing assembly 30 and the generator 5 both are mounted on the motor supporter 2 . A lead 3 of the generator 5 sequentially passes through an internal passage of one leg of the motor supporter 2 and out of a lead hole in the air inlet pipe 6 so as to be connected to other components than the generator 5 . Of course, the above generator and the lead thereof are not limited to the above mounting mode, and may also be in other specific structural forms.
[0050] Still further, the turbine impeller 18 can be fixedly connected to a rear end of the transmission shaft 28 through a fastening bolt 21 . The compressor impeller 7 can be fixedly connected to a front end portion of the transmission shaft 28 through a tightening nut 29 , and the rotating shaft of the generator 5 can also be connected to a most front end of the transmission shaft through a nut. Of course, the generator 5 , the compressor impeller 7 and the turbine impeller 18 can also be fixedly connected to the transmission shaft 28 in other ways. An air filtering assembly 1 can also be provided at an inlet opening portion of the air inlet pipe 6 of the compressor, so as to preliminarily filter the normal-temperature air 32 , thus preventing dust or impurities in the air from going into the compressor and ensuring the working stability and reliability of the thermoelectric device.
[0051] The diffusing pipe 27 of the compressor is an annular space formed between an end surface of a positioning boss 56 on the front flange 11 of the intermediate body 12 and a corresponding portion of a compressor volute 8 . By employing the diffusing pipe 27 with this structural shape, it is possible to more quickly reduce the flowing speed, temperature and increase the pressure of the air going into the compressor, so as to form high-pressure air 10 .
[0052] It is possible to further arrange the thermoelectric conversion device in other specific structural forms.
[0053] In another specific embodiment, a heat insulation plate 46 is provided between the rear flange 24 of the intermediate body 12 and the turbine volute 17 . The rear flange 24 can be provided thereon with a positioning clamping ring 54 which fixes the heat insulation plate 46 onto the turbine volute 17 . An annular nozzle 16 is formed between the heat insulation plate 46 and a vertical rear side wall of the turbine volute 17 . Because the high-temperature airflow enters into the annular nozzle 16 , and expands in the nozzle 16 so as to achieve pressure reduction, temperature reduction and speed increase, the heat insulation plate 46 provided between the intermediate body 12 and the turbine volute 17 is able to avoid the heat of the high-temperature air from diffusing outside of the volute and causing unnecessary heat loss, so that the heat of the high-temperature air is fully utilized and the conversion rate and working reliability of the thermoelectric conversion device are increased.
[0054] Of course, the specific structural form of the heat insulation plate 46 is not limited herein. For example, the heat insulation plate 46 can be provided thereon with means such as heat insulating groove, heat insulating slot and heat insulating coating, or a structural form such as multi-layer heat insulation can by employed. Any heat insulation plate 46 arranged between the rear flange 24 of the intermediate body 12 and the turbine volute 17 and functioning to insulate heat is deemed to fall into the protection scope of the present application.
[0055] In a further solution, referring to FIGS. 4 and 5 , FIG. 4 is a sectional view taken along line B-B in FIG. 1 ; and FIG. 5 is a partial enlarged view of part III in FIG. 4 . At least one airflow guide vane 49 for adjusting the injection-expansion ratio of airflow within the nozzle 16 is provided in the nozzle 16 . Specifically, the heat insulation plate 46 may be provided with a through hole oriented in fore-and-aft direction, and an outer end of the airflow guide vane 49 is pivotally connected in the through hole, so that an inner end of the airflow guide vane 49 swings as the outer end rotates in the through hole.
[0056] By employing this structural form, when the thermoelectric conversion device is in normal operation, the guide vane 49 is located at a position b. When the pressure and flow of the high-temperature air 23 going into the turbine air inlet 22 is lower than the design value, the outer end of the airflow guide vane 49 pivotally connected to the heat insulation plate 46 can be rotated to drive the inner end of the airflow guide vane 49 to swing to a position a, so as to reduce the outlet cross-sectional area of the nozzle 16 and increase the flowing velocity of the air when it goes into the turbine impeller 18 . As a result, the rotating speed of the turbine is increased and the boost pressure and air supply amount for the compressor are increased correspondingly, thereby increasing the flowing speed and pressure of the air going into the turbine. When the pressure and flow of the high-temperature air going into the turbine air inlet 22 is higher than the design value, the airflow guide vane 49 can be rotated to a position c, so as to increase the outlet cross-sectional area of the nozzle 16 and reduce the flowing speed of the high-temperature air 23 . As a result, the rotating speed of the turbine is reduced and the supply air pressure and supply air flow for the compressor are reduced, thereby reducing the flowing speed and pressure of the air going into the turbine, so as to avoid overspeed of the system.
[0057] As can be seen from the above adjusting process, the rotating speed of the turbine impeller 18 can be adjusted by mounting the airflow guide vane 49 , so that the rotating speed of the system when it is operating is within the design range, thus avoiding excessive fluctuation of the rotating speed of the turbine impeller 18 due to larger fluctuation in solar radiation and so on. As compared with the prior art, the working stability and robustness of the thermoelectric conversion device are significantly improved, so that it has better anti-interference performance.
[0058] The thickness in the fore-and-aft direction and the length from the outer end to the inner end of the airflow guide vane 49 are not limited in the above specific embodiment. The thickness in the fore-and-aft direction of the airflow guide vane 49 can fully or partially occupy the space between the heat insulation plate 46 and the vertical side wall of the turbine volute 18 . The length from the outer end to the inner end of the airflow guide vane 49 can be slightly larger, or smaller than the radial width of the annular nozzle 16 . The user can make options according to the magnitude of shifting angle and the magnitude of target adjusting amount.
[0059] Of course, the airflow guide vane 49 is not limited to the above mode and can be in other modes. For example, the inner end of the airflow guide vane 49 may be connected fixedly and pivotally to the heat insulation plate 46 , and the injection-expansion ratio of the airflow within the nozzle 16 may be adjusted through the outer end of the airflow guide vane 49 . For another example, the airflow guide vane 49 can also be inserted into the heat insulation plate 46 in such a manner to be slidable in the fore-and-aft direction. When the fluctuation in rotating speed is relatively large, the airflow guide vane 49 is driven to slide in the fore-and-aft direction. The rotating speed of the turbine impeller 18 may be adjusted by changing the thickness of airflow guide vane 49 in the fore-and-aft direction. In addition, the airflow guide vane 49 adjusting the flow can also be in other specific structural forms.
[0060] It should be noted that the orientation word “outer” used herein refers to the direction along which the air diffuses outwards from the center of the turbine impeller 18 in the end surface of the volute, that is, the direction from bottom to top in FIG. 5 . The orientation word “inner” is contrary to the above direction, that is, the direction from top to bottom in FIG. 5 . The term “end surface” refers to the surface in the vertical direction in FIG. 1 . It should be appreciated that these orientation words are established based on the accompanying drawings, and the presence thereof should not affect the scope of protection of the present application.
[0061] Referring to FIGS. 6 , 7 and 8 , FIG. 6 is a partial enlarged view of part II in FIG. 1 ; FIG. 7 is a sectional view taken along line C-C in FIG. 6 ; and FIG. 8 is a view seeing from the direction F in FIG. 1 .
[0062] In a more specific solution, as shown in FIGS. 6 , 7 and 8 , a rear side wall of the intermediate body 12 is provided with an arc-shaped hole 53 , and a shift lever 15 slidable along the arc of the arc-shaped hole 53 is inserted into the arc-shaped hole 53 . The shift lever 15 passes through a rear end of the intermediate body 12 to be connected to a slide ball 42 that rotates in an end surface along with the shift lever 15 . A shift fork 48 is provided at the front side of the heat insulation plate 46 . The outer end of the airflow guide vane 49 is fixedly connected between two fork-shaped portions of the shift fork 48 , and a straight-bar portion of the shift fork 48 is slidably inserted into a through hole of the slide ball 42 .
[0063] By employing this structural form, when the pressure and flow of the high-temperature air 23 going into the turbine air inlet 22 is higher or lower than the design value, the shift lever 15 is rotated so as to slide in the arc-shaped hole 53 and drive the slide ball at the rear end of the shift lever 15 to rotate accordingly. Because the fork-shaped portions of the shift fork 48 are fixedly connected to the airflow guide vane and the straight-bar portion of the shift fork 48 is slidably inserted into a through hole of the slide ball 42 , the rotation of the slide ball 42 in the end surface can drive the fork-shaped portions of the shift fork 48 to rotate appropriately, thereby driving the outer end of the airflow guide vane 49 fixedly connected to the fork-shaped portions to rotate. As a result, the adjustment of the injection-expansion ratio of the airflow within the nozzle 16 is achieved.
[0064] Thus, as can be seen, by employing the above manipulating structure, when the angle of the airflow guide vane 49 is adjusted as desired, the operator merely shifts the shift lever 15 , so that it slides in the arc-shaped hole 53 , thereby achieving the angle adjustment of the airflow guide vane 49 , which simplifies the operation of flow adjustment. When the fluctuation in solar radiation is relatively large, the adjusting process can be completed rapidly, thus having a good responsibility.
[0065] Of course, the mode of fixed connection between the fork-shaped portions at the outer end of the shift fork 48 and the outer end of the airflow guide vane 49 is not limited in the above specific embodiment, and the fork-shaped portions can be fixedly connected to a rotating shaft 50 , inserted into a through hole of the heat insulation plate 46 , of the airflow guide vane 49 via a pin assembly 51 . A retaining sleeve 52 can also be provided between the through hole of the heat insulation plate 46 and the rotating shaft 50 of the airflow guide vane 49 , and is also fixedly connected to the fork-shaped portions of the shift fork 48 . The provision of the retaining sleeve 52 herein can have a certain protective action on the rotating shaft 50 of the airflow guide vane 49 and avoid the rotating shaft 50 from subjecting larger wear due to excessive rotation, which would otherwise cause hot air leakage and so on.
[0066] The specific structural form by which the shift lever 15 drives the slide ball 42 to rotate is not limited in the above specific embodiment. Specifically, a clamp structure can be fixedly connected to the rear end of the shift lever 15 and the slide ball 42 can be clamped in the clamp structure so that the slide ball 42 can be freely rotated but can not be moved in the inward-outward direction. More specifically, a major clamp piece 43 and a minor clamp piece 47 can be arranged at two sides of the slide ball 42 , and the major clamp piece 43 and the minor clamp piece 47 are connected as one piece through a fastening assembly 44 . A retaining ring 45 can also be provided at an inner end of the major clamp piece 43 . The retaining ring 45 presses the clamp assembly against the front side of the heat insulation plate 46 , so that the clamp structure can be rotated about the inner end thereof in the end surface.
[0067] In summary, the operation for adjusting the injection-expansion ratio within the nozzle 16 can be stated completely as follow: firstly, the shift lever 15 is manipulated so that it slides in the arc-shaped hole 53 , thereby driving the outer end of the clamp structure to rotate about the inner end thereof and thus driving the slide ball 42 in the clamp assembly to rotate therewith; then, the straight-bar portion of the shift fork 48 is driven to slide in the slide ball 42 , and the fork-shaped portions of the shift fork 48 drive the rotating shaft 50 of the airflow guide vane 49 to rotate, thereby achieving the position change of the airflow guide vane 49 so as to adjust the injection-expansion ratio within the nozzle 16 ; and thus, adjustment of the rotating speed of the turbine impeller 18 is achieved finally.
[0068] Thus, as can be seen, the above manipulating device, in which movement is transferred sequentially from the shift lever 15 , the clamp structure, the slide ball 42 , the shift fork 48 to the airflow guide vane 49 , has the technical effects such as easy manipulation, convenient control and actuate adjustment. Of course, the manipulating device for the airflow guide vane 49 is not limited to the above specific structural form and can also be a variety of other manipulation modes.
[0069] A lubricating system and a cooling system may further be provided in the above thermoelectric conversion device.
[0070] Referring to FIGS. 9 and 10 in conjunction with FIG. 1 , FIG. 9 is a partial enlarged view of part I in FIG. 1 ; and FIG. 10 is a longitudinal sectional schematic view of the intermediate body 12 .
[0071] In another specific embodiment, the intermediate body 12 is rotatably connected with the transmission shaft 28 through floating bearings 37 . A thrust bearing 35 is provided in front of the floating bearings 37 . An oil inlet hole 13 is provided at the top end of the intermediate body 12 . Lubrication passages 36 leading to the two floating bearings 37 and the thrust bearing 35 are provided at the bottom end of the oil inlet hole 13 . An oil outlet hole 25 is further provided at the bottom end of the intermediate body 12 . A thrust ring 38 and a transition ring 39 are further provided in front of the thrust bearing 35 . The thrust ring 38 cooperates with a shaft shoulder of the transmission shaft 28 and a thrust face of the thrust bearing 35 , and the transition ring 39 cooperates with the compressor turbine 7 and the thrust face of the thrust bearing 35 . An oil baffle plate 26 is provided on a lower end of a transition ring 39 , and the lower end of the oil baffle plate 26 is arranged to be inclined towards the oil outlet hole 25 .
[0072] By employing this structural form, lubricating oil 14 enters through an oil inlet hole 13 of the intermediate body 12 and is sent to friction pairs of the floating bearing 37 and the thrust bearing through the lubrication passages 36 , so as to lubricate the friction surfaces while taking away heat generated by rotational friction. The lubricating oil 14 with elevated temperature flows out from an oil outlet hole 25 arranged at a lower portion of the intermediate body 12 . In addition, most of the lubricating oil 14 that flows out from the front thrust bearing 35 will drip on the oil baffle plate 26 , then slip along the oil baffle plate 26 to the oil outlet hole 25 and flow out.
[0073] Thus, as can be seen, by employing this structure, most of the lubricating oil 14 can be introduced into the intermediate body 12 for lubricating and cooling the bearings, and is discharged from the intermediate body 12 by the guiding effect of the oil baffle plate 26 , thus producing the technical effects such as simple structure and easy manufacture and processing. Specifically, the thrust bearing 35 can be further provided with an oil hole aligned with the lubricating oil passage 36 to guide the lubricating oil 24 , so as to achieve a better lubrication effect. Of course, the thrust bearing 35 and the lubrication passage 36 can also be communicated with each other in other specific ways.
[0074] In a further solution, a bearing cover 41 is provided at a front end of the transition ring 39 and in front of the thrust bearing 35 . The bearing cover 41 is axially fixed to the thrust bearing 35 by a retaining ring 33 . A sealing element 34 is provided at contacting areas. An oil throwing plate 40 projecting towards the outside of the transmission shaft 28 is further provided on the transition ring 39 between the sealing element 34 and the oil baffle plate 26 .
[0075] By employing this structure, a part of the lubricating oil 14 after lubricating and cooling the bearings flows towards the transition ring 39 and is blocked by the oil throwing plate 40 , and then is thrown to a side wall of the bearing cover 41 under the action of centrifugal force and flows down, thus forming dynamic seal. When the device is in operation, after a small amount of the lubricating oil 14 immerses the oil throwing plate 40 , it will be sealed by the seal assembly 34 with static seal. In summary, by the oil baffle plate 26 , the oil throwing plate 40 on the transition ring 39 and the seal assembly 34 , it can be ensured that the lubricating oil 14 will not leak out from a side, close to the compressor, of the intermediate body 12 , thus having a good sealing performance.
[0076] Similarly, in order to ensure that the lubricating oil 14 will not leak out from a side, close to the turbine, of the intermediate body 12 , a projecting ring is provided at the rear side of the rear floating bearing 37 of the transmission shaft 28 , and the sealing element 34 is provided at contacting areas between the projecting ring and a side wall of the intermediate body 12 .
[0077] By employing this structure, the lubricating oil 14 that flows out from the floating bearing 37 on the turbine side will directly drip on the side wall of the intermediate body 12 firstly, and then flow towards the oil outlet hole 25 . Even if a small amount of the lubricating oil 14 will infiltrate towards the turbine side along the transmission shaft 28 , it can be thrown to the surrounding by the projecting ring on the transmission shaft 28 , thus preventing the lubricating oil 14 from leaking outwards. When the system is not in operation, a small amount of the lubricating oil 14 infiltrates towards the turbine side along the transmission shaft 28 and will be sealed by the seal assembly 34 with static seal, thus ensuring that the lubricating oil 14 will not leak from the turbine side.
[0078] In another specific embodiment, as shown in FIG. 10 , the intermediate body 12 has a cavity structure, and two bearing seat holes 55 arranged coaxially are provided in the middle of the intermediate body 12 . A positioning ring 56 for positioning and connecting to the compressor is provided on the front flange 11 of the intermediate body 12 , and a positioning and clamping ring 54 for clamping and positioning relative to the turbine is provided on the rear flange 24 of the intermediate body 12 . The oil inlet hole 13 is provided in the top of the intermediate body 12 at a middle position. Three paths are formed from the oil inlet hole 13 , two of which lead to the two bearing seat holes 55 respectively, and the other of which leads to a hole in which the thrust bearing 35 is mounted. The oil outlet hole 25 is provided in the bottom of the intermediate body 12 at a middle position. Of course, the oil inlet hole 13 and the oil outlet hole 25 are not limited to be provided at the middle position of the intermediate body. The intermediate body 12 is not limited to the above structure, and can also employ other structural forms.
[0079] The present application also provides a solar thermal power generation system, which includes a heat collector and further includes the above thermoelectric conversion device. The thermoelectric conversion device is connected to an output end of the heat collector.
[0080] Because the thermoelectric conversion device has the above technical effects, the solar thermal power generation system including the thermoelectric conversion device also has the corresponding technical effects, which will not be described in detailed herein.
[0081] The solar thermal power generation system and thermoelectric conversion device thereof according to the present application has been described in detail above. The principle and embodiments of the present application are described herein by using specific examples, and the description of the above embodiments is only used to help understanding the method and the core idea of the present application. It should be noted that, those skilled in the art may make various improvements and modifications to the present application without departing from the principle of the present application, and these improvements and modifications should also fall into the protection scopes of the claims of the present application.
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A solar-energy heat power-generating system and thermoelectric conversion device thereof, the thermoelectric conversion device comprising a power generator ( 5 ), an air compressor, a turbine and an intermediate body ( 12 ) fixedly connected between the air compressor and the turbine; the interior of the intermediate body ( 12 ) is rotatably connected to a transmission shaft ( 28 ); the transmission shaft ( 28 ) is fixedly connected to the rotating shaft of the power generator ( 5 ); the air compressor impeller ( 7 ) of the air compressor and the turbine impeller ( 18 ) of the turbine are both installed on the transmission shaft ( 28 ); the power generator ( 5 ) is also connected to a conducting wire ( 3 ) for inputting current; the solar-energy heat power-generating system comprises a heat collector and the thermoelectric conversion device; the air compressor of the thermoelectric conversion device is located upstream of the heat collector, and the turbine is located downstream of the heat collector.
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RELATIONSHIP TO PRIOR APPLICATION
This patent application is a Divisional patent application relating to U.S. Non-Provisional application Ser. No. 12/904,194 filed Oct. 14, 2010, which relates to U.S. Provisional Patent Application Ser. No. 61/252,197 filed Oct. 16, 2009.
BACKGROUND OF THE INVENTION
Physical contact optical fiber connectors are widely used in the communication industry. These connectors have one or more optical fiber physical contacts which are supported by ferrules which also physically align the contacts. These optical fiber physical contacts are often formed by polishing the end face of the optical fiber to a precise radius of curvature. A connector actually includes two connector halves which are intermatable. However, a connector half is often simply referred to as a connector. Thus, the single or multiple contacts are actually received within a connector half. When a corresponding connector half containing fibers and contacts are mated with the other connector half, the optical fiber contacts are brought together at their respective radii of curvature. If the intermated surfaces of the optical contacts are clean and undamaged, the contacts should have reasonably low insertion loss and small back reflection. In addition, it is important to correctly match these intermated optical contacts; for example, the corresponding intermated contacts must be correctly sized and aligned. Ideally, two fibers should be optically and physically identical and held by a connector that aligns the fibers precisely so that the interconnection does not exhibit any influence on the light propagation there through. This ideal situation is impractical because of many reasons, including fiber properties and tolerances in the connector.
The ends of the fibers or contacts have been prepared by several methods, including scoring and breaking the fibers, as well as polishing the ends. Optical fiber connector contacts having very low back reflection become more important at higher data rates. The current practice to obtain low back reflection is to angle polish the physical contact. However, because of this angle, the connector must be keyed to have the proper orientation to mate with its corresponding angle-polished contact.
SUMMARY OF THE INVENTION
In accordance with one form of this invention, there is provided a fiber optic connector for use with a fiber optic network having at least one predetermined operating wavelength. A first housing containing at least one optical fiber is provided. The optical fiber has a free end forming a physical contact. The physical contact is coated with a protective film. The optical thickness of the protective film is at least 0.10 of the operating wavelength of the fiber optic network.
In accordance with another form of this invention, there is provided a fiber optic connector for use with a fiber optic network having at least one predetermined operating wavelength including a first housing. The first housing contains at least one optical fiber. The optical fiber has a free end forming a physical contact. The physical contact is thermally shaped. The thermally shaped terminus is coated with a thin protective film. The optical thickness of the film is less than twice the operating wavelength of the fiber optic network, but is at least 0.10 of the operating wavelength.
In accordance with yet another form of this invention, there is provided a method for manufacturing a fiber optic connector including providing a length of at least one optical fiber. The optical fiber has first and second free ends. The first free end forms a physical contact. A quick connect device is attached to the optical fiber wherein the physical contact projects from one end of the quick connect device and a portion of the optical fiber projects from the other end of the quick connect device thereby forming a termini. A vacuum is applied to the termini. The physical contact is coated with a protective film while the vacuum is applied.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is set forth in the independent claims. The invention, however, may be better understood in reference to the accompanying drawings in which:
FIG. 1 is a simplified partial side elevational view showing two mating optical fiber physical contacts of the subject invention.
FIG. 2 is a perspective view showing a fiber optic connector and a plurality of the fiber optic contacts of FIG. 1 .
FIG. 3 is a front view of the fiber optic connector of FIG. 2 .
FIG. 4 is a sectional view of the fiber optic connector of FIG. 3 taken through section line 4 - 4 .
FIG. 5 is a more detailed sectional view of a portion of fiber optic connector of FIG. 4 .
FIG. 6 is a perspective view showing a fiber optic termini with a quick connect device which may be used in connection with the apparatus of the subject invention.
FIG. 7 is a perspective view showing the quick connect device of FIG. 6 having been spliced to fiber optic cable.
FIG. 8 is a perspective view showing an apparatus used in the manufacture of the optical fiber physical contacts of the subject invention.
FIG. 9 is a sectional view showing one of the holes in the apparatus of FIG. 8 receiving a termini and a quick connect of FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now more particularly to FIG. 1 , there is provided optical fiber 10 , having core 12 and cladding 14 . There is also provided optical fiber 16 , having core 18 and cladding 20 . Fiber 10 is encapsulated by alignment ferrule 21 and fiber 11 is encapsulated by alignment ferrule 23 . As will be discussed below, optical fibers 10 and 16 are mounted in corresponding connector halves which are designed to be intermated.
Optical fiber 10 includes tip 22 , which forms a physical contact. Optical fiber 16 includes tip 24 , which forms a corresponding physical contact. These contacts 22 and 24 are preferably not angle polished, but preferably have coating thickness adjusted for low reflection and may be thermally shaped for additional reflection reduction.
This thermal shaping may be done by various methods known to those skilled in the art, including the methods taught in U.S. Pat. Nos. 6,413,450 and 6,738,554, both assigned to Megladon Manufacturing Group. The teachings of these two Megladon Patents are hereby incorporated herein by reference.
Each physical contact 22 and 24 is coated with thin film 26 , which is made of a hard material, i.e., a material having a Knopp hardness which is greater than the Knopp hardness of optical fibers. The preferred coating material is Al 2 O 3 , also known as corundum. Corundum is a very hard material, and thus resists scoring. Other hard coatings may also be used. Preferably this corundum film is thin enough so that light passing through is substantially unaffected, i.e., insertion losses are low but thick enough to resist scoring, and the optical thickness is adjusted so that reflection is low. For the embodiments in which a single layer of the film is applied, the thickness of film 26 should be at least 0.10 of but less than 1.00 of the operating wavelength of the light within the fibers. For embodiments in which multiple layers of film are applied, the thickness of the film can be as high as 2.00 of the operating wavelength of the light within the fibers.
FIG. 2 shows a plurality of optical fibers 10 having physical contacts 22 all of which are mounted in connector body 28 . Multi-fiber cable 30 extends from the rear of connector body 28 . Preferably the embodiment of FIG. 2 utilizes quick connect optical fiber device as shown in FIG. 6 which are known to those skilled in the art such as the quick connect devices described in U.S. Patent Publication No. US2009/0060427 invented by Wouters. The teachings of the Wouters Patent Publication are hereby incorporated herein by reference.
FIG. 6 shows termini 34 including quick connect device 37 , optical fiber 10 and physical contact 22 , physical contact is coated at the tip by corundum film 26 . After coating, which is described below, termini 34 is placed in connector body 28 , and optical fiber 10 is spliced to a corresponding optical fiber located within cable 30 by a splicing technique known to those skilled in the art. A spliced cable 30 /termini 34 is shown in FIG. 7 with the splicing area indicated as item 35 . Preferably, contact 22 has been thermally shaped, although the invention is not limited to a thermally shaped contact.
It is preferred that corundum thin film coating 26 is applied to the contacts in a vacuum chamber using a coating process known to those skilled in the art. In embodiments in which the connector is terminated to a reel of optical fiber cable, if quick connect optical fiber termini are not used, the reel, which can be very large depending on the length of the cable, must be placed within the vacuum chamber which can be impractical and expensive. Using termini 34 , individual termini may be placed in the vacuum chamber for disposition of the corundum coating application without the cable attached since the termini may be spliced onto the cable after coating of the film has taken place. A single layer vacuum coating run is expensive, and there could be several layers for the embodiment in which the film is used or an anti-reflective coating in addition to providing the hardware discussed above. In addition, each item will need to be rotated inside of the vacuum chamber during the coating process. By using the quick connect optical fiber termini approach, many more contacts can be coated at the same time with a single coating run, and/or a smaller vacuum chamber may be used, resulting in a substantial money savings. If the connector is terminated to a short patch cord(s) the quick-terminated optical fiber termini are not needed since a short patch cord(s) will easily fit into the vacuum chamber.
During the coating process, it is important that only the tip 22 of the optical fiber be coated since the coating materials are very expensive and it would be wasteful to coat other parts of the termini.
FIG. 8 illustrates a plate 36 which may be used to segregate the fiber tips 22 from the remainder of the termini during the coating process. Plate 36 includes a plurality of holes 38 which are adapted to receive termini 34 so that the tip 22 projects below the bottom of plate 36 and the remainder of the termini projects above the plate 36 as shown in FIG. 9 . For illustration purposes only, a single termini is shown. In reality, it is preferred that each hole in plate 36 receives a termini for the sake of efficiency. Plate 36 is sized with a protective cover on the top of the plate within the vacuum chamber such that the coating occurs in the bottom of the plate, and only the tips 22 are coated. Plate 36 is also rotatable so that the coating is uniform. Once the tips 22 have been coated, termini 34 are removed from the plate and thus from the vacuum chamber and inserted into connector 28 as illustrated in FIGS. 4 and 5 . Termini 34 is spliced to optical fiber 40 , which is received within cable 30 , at splice region 35 using splicing techniques known to those skilled in the art, including techniques described in the Wouters patent publication.
The hard corundum coating can be applied onto several layers of anti-reflective coating to also form a thicker hardened anti-reflective coating, which may in some instances eliminate the need for thermally shaping the contact. In some multi-layer embodiments, the outer layer may be hard corundum and the inner layers may be made of other low or high index of refraction materials having hardness closer to the glass fiber. This anti-reflective coating can be used for one or multiple wavelength bands of operation, including, but not limited to, the bands centered around 850 nm and 1,300 nm or 1,310 nm and 1,550 nm for example. The thickness of the anti-reflective coating depends on the number of layers of the film which are used. For example, the thickness might vary between 0.10 and 2.00 times the operating wavelength. However, where thermally shaping is used, the hardened coating further increases the hardness of the thermally shaped contact.
Multi fiber circular connectors, such as the one shown in FIG. 2 , are often used in harsh environments. Since such connectors must be keyed if the contacts are angle-polished, the contact orientations are hard to maintain. The combination of a hardened surface, scratch resistant contact and low back reflection without the need for keyed contact orientation is a great benefit for harsh environment multi-fiber circular connectors.
The physical contact fiber end faces described herein are axially symmetric, rugged and have low back reflection and may be used with single or multi-fiber connectors.
From the foregoing description of various embodiments of the invention, it will be apparent that many modifications may be made therein. It is understood that these embodiments of the invention are exemplifications of the invention only and that the invention is not limited thereto.
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A fiber optic connector for use with a fiber optic network having at least one predetermined operating wavelength is provided. First housing contains at least one optical fiber. The optical fiber has a free end forming a physical contact. The physical contact is coated with a protective film. The optical thickness of the protective film is at least 0.10 of the operating wavelength of the fiber optic network. Preferably, the physical contact is thermally shaped. Also preferably, the optical fiber is attached to a quick connect device forming a termini. The physical contact of the optical fiber can be readily coated with the protective film by placing the termini in a vacuum chamber.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to systems and methods for producing or delivering heat at or near the down hole end of production tubing of a producing oil or gas well for improving production therefrom.
[0003] 2. Background Information
[0004] Free-flowing oil is increasingly difficult to find, even in oil wells that once had very good flow. In some cases, good flowing wells simply “clog up” with paraffin. In other cases, the oil itself in a given formation is of a viscosity that it simply will not flow (or will flow very slowly) under naturally ambient temperatures.
[0005] Because the viscosity of oil and paraffin have an inverse relationship to their temperatures, the solution to non-flowing or slow flowing oil wells would seem fairly straight forward—somehow heat the oil and/or paraffin. However, effectively achieving this objective has proven elusive for many years.
[0006] In the context of gas wells, another phenomena—the buildup of iron oxides and other residues that can obstruct the free flow of gas through the perforations, through the tubing, or both—creates a need for effective down hole heating.
[0007] Down hole heating systems or components for oil and gas wells are known (hereafter, for the sake of brevity, most wells will simply be referred to as “oil wells” with the understanding that certain applications will apply equally well to gas wells). In addition, certain treatments (including “hot oil treatments”) for unclogging no-flow or slow-flow oil wells have long been in use. For a variety of reasons, the existing technologies are very much lacking in efficacy and/or long-term reliability.
[0008] The present invention addresses two primary shortcomings that the inventor has found in conventional approaches to heating oil and paraffin down hole: (1) the heat is not properly focused where it needs to be; and (2) existing down hole heaters fail for lack of design elements which would protect electrical components from chemical or physical attack while in position.
[0009] The present inventor has discovered that existing down hole heaters inevitably fail because their designers do not take into consideration the intense pressures to which the units will be exposed when installed. Such pressure will force liquids (including highly conductive salt water) past the casings of conventional heating units and cause electrical shorts and corrosion. Designers with whom the present inventor has discussed heater failures have uniformly failed to recognize the root cause of the problem—lack of adequate protection for the heating elements and their electrical connections. The down hole heating unit of the present invention addresses this shortcoming of conventional heating units.
[0010] Research into the present design also reveals that designers of existing heaters and installations have overlooked crucial features of any effective down hole heater system: (1) it must focus heat in such a way that the production zone of the formation itself is heated; and (2) heat (and with it, effectiveness) must not be lost for failure to insulate heating elements from up hole components which will “draw” heat away from the crucial zones by conduction.
[0011] However subtle the distinctions between the present design and those of the prior art might at first appear, actual field applications of the present down hole heating system have yielded oil well flow rate increases which are multiples of those realized through use of presently available down hole heating systems. The monetary motivations for solving slow-flow or no-flow oil well conditions are such that, if modifying existing heating units to achieve the present design were obvious, producers would not have spent millions of dollars on ineffective down hole treatments and heating systems (which they have done), nor lost millions of dollars in production for lack of the solutions to long-felt problems that the present invention provides (which they have also done).
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to provide an improved down hole heating system for use in conditioning oil and gas wells for increased flow, when such flow is impeded because of viscosity and/or paraffin blockage conditions.
[0013] It is another object of the present invention to provide an improved design for down hole heating systems which has the effect of more effectively focusing heat where it is most efficacious in improving oil or gas flow in circumstances when such flow is impeded because of oil viscosity and/or paraffin blockage conditions.
[0014] It is another object of the present invention to provide an improved design for down hole heating systems for oil and gas wells which design renders the heating unit useful for extended periods of time without interruption for costly repairs because of damage or electrical shorting caused by unit invasion by down hole fluids.
[0015] It is another object of the present invention to provide an improved method for down hole heating of oil and gas wells for increasing flow, when such flow is impeded because of viscosity and/or paraffin blockage conditions.
[0016] In satisfaction of these and related objects, the present invention provides a down hole heating system for use with oil and gas wells which exhibit less than optimally achievable flow rates because of high oil viscosity and/or blockage by paraffin (or similar meltable petroleum byproducts). The system of the present invention, and the method of use thereof, provides two primary benefits: (1) the involved heating unit is designed to overcome an unrecognized problem which leads to frequent failure of prior art heating units—unit invasion by down hole heating units with resulting physical damage and/or electrical shortages; and (2) the system is designed to focus and contain heat in the production zone to promote flow to, and not just within, the production tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is an elevational view of a producing oil well with the components of the present down hole heating system installed.
[0018] [0018]FIG. 2 is an elevational, sagittal cross section view of the heating unit of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Referring to FIG. 1, the complete down hole heating system of the present invention is generally identified by the reference numeral 10 . System 10 includes production tubing 12 (the length of which depends, of course, on the depth of the well), a heat insulating packer 14 , perforated tubing 16 , a stainless steel tubing collar 18 , and a heating unit 20 .
[0020] Referring in combination to FIGS. 1 and 2, heating unit 20 includes electrical resistance type heater rods 26 , the electrical current for which is supplied by cables 22 which run down the exterior of production tubing 12 and connect to leads 24 at the upper end of heating unit 20 .
[0021] Heat insulating packer 14 and stainless steel collars 18 are includes in their stated form for “containing” the heat from heating unit 20 within the desired zone to the greatest practical degree. Were it not for these components, the heat from heating unit 20 would (like the heat from conventional down hole heater units) convect and conduct upward in the well bore and through the production tubing, thereby essentially directing much of the heat away from the area which it is most needed—the production zone.
[0022] Perhaps, it goes without saying that oil that never reaches the pump will never be produced. However, this truism seems to have escaped designers of previous down-hole heating schemes, the use of which essentially heats oil only as it enters the production tubing, without effectively heating it so that it will reach the production tubing in the first place. Largely containing the heat below the level of the junction between the production tubing 12 and the perforated tubing 16 , as is achieved through the current design, has the effect of focusing the heat on the production formation itself. This, in turn, heats oil and paraffin in situ and allows it to flow to the well bore for pumping, thus “producing” first the viscous materials which are impeding flow, and then the desired product of the well (oil or gas). Stainless steel is chosen as the material for the juncture collars at and below the joinder of production tubing 12 and perforate tubing 16 because of its limited heat conductive properties.
[0023] Physical and chemical attack of the electrical connections between the power leads and the heater rods of conventional heating systems, as well as shorting of electrical circuits because of invasion of heater units by conductive fluids is another problem of the present art to which the present invention is addressed. Referring to FIG. 2, the present inventor has discovered that, to prevent the aforementioned electrical problems, the internal connection for a down hole heating unit must be impenetrably shielded from the pressures and hostile chemical agents which surround the unit in the well bore.
[0024] As shown in FIG. 2, a terminal portion of the heater rods 26 which connect to leads 24 are encased in a cement block 28 of high temperature cement. The presently preferred “cement” is an epoxy material which is available as Sauereisen Cement #1, and which may be obtained from the Industrial Engineering and Equipment Company (“Indeeco”) of St. Louis, Mo., USA. Cement block 28 is, in turn, encased in a steel fitting assembly 30 (“encasement means”), each component of which is welded with continuous beads to each adjoining component. To safely admit leads 24 to the interior of heating unit 20 , a CONAX BUFFALO sealing fitting 32 (available from the Conax Buffalo company of Buffalo, N.Y., USA) is used to transition the leads 24 from outside the production tubing 12 to inside heating unit 20 where they connect with rods 26 .
[0025] Fitting assembly 30 and sealing fitting 32 are, as would be apparent to anyone skilled in the art, designed to threadingly engage heating unit 20 to the perforated tubing which is up hole from heating unit 20 .
[0026] The shielding of the electrical connections between leads 24 and rods 26 is crucial for long-term operation of a down hole heating system of the present invention. Equally important is that power is reliably delivered to that connection. Therefore, solid copper leads with KAPTON insulation are used, such leads being of a suitable gauge for carrying the intended 16.5 Kilowatt, 480 volt current for the present system with its 0.475 inch diameter INCOLOY heater rods 26 (also available from Indeeco).
[0027] The present invention includes the method for use of the above-described system for heat treating an oil or gas well for improving well flow. The method would be one which included use of a down hole heating unit with suitably shielded electrical connections substantially as described, along with installation of the heat-retaining elements also as describe to properly focus heat on the producing formation.
[0028] In addition to the foregoing, it should be understood that the present method may also be utilized by substituting cable (“wire line”) for the down hole pipe for supporting the heating unit 20 while pipe is pulled from the well bore. In other words, one can heat-treat a well using the presently disclosed apparatuses and their equivalents before reinserting pipe, such as during other well treatments or maintenance during which pipe is pulled. It is believed that this approach would be particularly beneficial in treating deep gas wells with an iron sulfide occlusion problem.
[0029] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.
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A down hole heating system for use with oil and gas wells which exhibit less than optimally achievable flow rates because of high oil viscosity and/or blockage by paraffin (or similar meltable petroleum byproducts). The heating unit the present invention includes shielding to prevent physical damage and shortages to electrical connections within the heating unit while down hole (a previously unrecognized source of system failures in prior art systems). The over-all heating system also includes heat retaining components to focus and contain heat in the production zone to promote flow to, and not just within, the production tubing.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a non-provisional patent application based on U.S. Provisional Application Ser. No. 62/193,791, entitled “AIRFLOW MONITOR FOR USE WITH A VACUUM POWERED SEWER SYSTEM”, filed Jul. 17, 2015, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a monitoring device to detect a defective or stuck vacuum operated valve of a vacuum sewer system.
[0004] 2. Description of the Related Art
[0005] A vacuum sewer system is a method of transporting sewage from its source to a sewage treatment plant using negative air pressure. It uses the difference between atmospheric pressure and a partial vacuum maintained in the piping network and vacuum station collection vessel. This differential pressure allows a central vacuum station to collect the wastewater of individual homes.
[0006] The main components of a vacuum sewer system are collection chambers and vacuum valves, sewers, a central vacuum station and monitoring and control components.
[0007] Vacuum technology is based on differential air pressure. Rotary vane vacuum pumps generate an operation pressure of −0.4 to −0.6 bar at the vacuum station, which is also the only element of the vacuum sewerage system that must be supplied with electricity. Interface valves, that are installed inside the collection chambers, work pneumatically. Sewage flows by means of gravity into each house's collection sump, after a certain fill level inside this sump is reached, the interface valve opens. The impulse to open the valve is usually transferred by a pneumatically (pneumatic pressure created by fill level) controlled controller unit. No electricity is needed to open or close the valve—the energy is provided by the vacuum itself. While the valve is open, the resulting differential pressure becomes the driving force and transports the wastewater towards the vacuum station. When the level of wastewater is lowered to a predetermined level the valve closes to stop the flow of air and wastewater until the level rises enough to trigger the opening of the valve again. Each collection sump has a vent pipe that extends up from the sump so that an unhindered flow of air can enter the sump when the valve is actuated. If the valve does not completely seal there is a flow of air that is effectively an inefficiency in the system since energy is needed to run the vacuum pump.
[0008] Once the wastewater arrives in the vacuum collection tank at the vacuum station, the wastewater is then pumped to the discharge point, which may be a gravity sewer or a treatment facility.
[0009] A weakness of the system lies in the functioning of the valves. The mechanical float switches that operate the valves require preventative maintenance for worn parts and seals. Also, the vacuum valves can get stuck open leading to pressure drops in the entire system. One technique to detect the stuck or non-closing valve is to walk up to a vent pipe and listen to hear a continuous flow of air. This is time consuming in that it has to be done for each sump at each home until the stuck valve(s) is (are) discovered.
[0010] What is needed in the art is an effective monitoring system that allows for the determination of the functioning of the valve from a distance.
SUMMARY OF THE INVENTION
[0011] The present invention provides a monitoring device to detect a defective or stuck vacuum operated valve of a vacuum sewer system.
[0012] The invention in one form is directed to a vacuum sewer system including at least one home collection system, a central vacuum system coupled to the home collection system and a vacuum valve monitoring system coupled to the home collection system. The vacuum valve monitoring system has an airflow detector and an indicator operatively coupled to the airflow detector, the indicator being configured to emanate an indication that the airflow detector has detected an airflow thereby.
[0013] The invention in another form is directed to a vacuum valve monitoring system that is coupled to at least one home collection system of a central vacuum system. The vacuum valve monitoring system has an airflow detector and an indicator operatively coupled to the airflow detector, the indicator being configured to emanate an indication that the airflow detector has detected an airflow.
[0014] An advantage of the present invention is that the functioning of a vacuum valve can be determined at a distance from the vent pipe, no longer requiring a person to listen for the flow of air
[0015] Another advantage of the present invention is that the airflow monitor is easily installed in existing vent pipes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
[0017] FIG. 1 is a schematical view of a vacuum sewer system using an embodiment of a valve monitoring system of the present invention;
[0018] FIG. 2 is a closer side view of the valve monitoring system of FIG. 1 ;
[0019] FIG. 3 illustrates a closer view of the airflow monitor or valve monitoring system itself of FIGS. 1 and 2 ;
[0020] FIG. 4 is a partially sectioned side view of the airflow monitor of FIG. 3 ;
[0021] FIG. 5 is a partially exploded schematical view of parts of the airflow monitor of FIGS. 1-4 ; and
[0022] FIG. 6 is a block diagram of the functional components of the airflow monitor of FIGS. 1-5 .
[0023] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring now to the drawings, and more particularly to FIG. 1 , there is shown a home collection system HCS coupled to a central sewer system CSS. Multiple home collection systems HCS are coupled to the central sewer system CSS. An airflow monitor 10 or vacuum valve monitoring system 10 of the present invention is installed in a typical vent pipe 12 connected to a holding tank or sump HT. Airflow monitor 10 is installed through a sidewall of vent pipe 12 and may be glued in place or may be mechanically secured, for example by being threaded thereto.
[0025] Central system CSS includes a vacuum system that provides a vacuum in pipe P. When the level of wastewater in holding tank HT achieves a predetermined level then valve V opens and the vacuum in pipe P pulls the wastewater from holding tank HT to central system CSS. Air flows into holding tank HT by way of vent pipe 12 until valve V closes when the level of wastewater in holding tank HT is lowered. Airflow monitor 10 detects the flow of air through vent pipe 12 and provides a signal when the airflow is occurring as discussed herein.
[0026] Now, additionally referring to FIG. 2 there is shown a closer view of vent pipe 12 with airflow monitor 10 installed therein. Airflow monitor 10 can be easily installed in existing vent pipes 12 by drilling a hole through the side of pipe 12 inserting monitor 10 from the inside of pipe 12 through the hole and threading a nut on the threaded portion of monitor 10 .
[0027] Now, additionally referring to FIGS. 3-5 , there are shown more details of airflow monitor 10 , which includes a base unit 14 , a securing means 16 , and a light diffuser or refractor 18 .
[0028] In base unit 14 there is an LED light 20 , a battery pack 22 , a Reed switch 24 , a magnet 26 and a flapper 28 . When an airflow moves past flapper 28 , which may be a diaphragm 28 it cause magnet 26 connected thereto to move, which in turn causes reed switch 24 to electrically close and conduct electricity from battery pack 22 to LED light 20 . Reed switch 24 along with magnet 26 and flapper 28 can be considered a sensor, which may be an integral unit. LED light 20 may be constantly illuminated or blink in a specific pattern to indicate the flow of air. This then allows the leaky valve V to be easily found and corrected.
[0029] During normal operation whenever the valve V is activated and there is an airflow then LED light 20 will illuminate. Since normal operation will then have the valve closing in a few seconds the constant activation (whether blinking or solidly illuminated) provides an alert that maintenance is needed.
[0030] It is also contemplated that a timing circuit 30 , as depicted in FIG. 6 may delay the activation of light 20 until a predetermined time, such as 20 seconds, 30 seconds or 1 minute, or some other predetermined time has passed. This allows airflow monitor 10 to never illuminate indicator 20 during normal operation of the sump and valve V.
[0031] FIG. 5 functionally illustrates the circuitry that effects the action described above. Here diaphragm 28 is pivotal about line 30 , so that airflow will cause diaphragm 28 to move about pivot 32 to cause the activation of airflow monitor 10 as described above.
[0032] It is also contemplated that a solar power cell may be used to provide power to battery pack 22 to maintain the operating condition thereof. It is further contemplated that some alternative alerting technique may be used instead of or in addition to light 20 . Even an infrared light 20 or some light or other signal not visible to humans might be used to send a signal that is then detected by use of a known detection device.
[0033] It is further contemplated that airflow monitor 10 would remain inactive until remotely triggered to function by way of a remote control not shown.
[0034] While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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A vacuum sewer system including at least one home collection system, a central vacuum system coupled to the home collection system and a vacuum valve monitoring system coupled to the home collection system. The vacuum valve monitoring system has an airflow detector and an indicator operatively coupled to the airflow detector, the indicator being configured to emanate an indication that the airflow detector has detected an airflow.
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TECHNICAL FIELD OF THE INVENTION
The invention relates to techniques for mounting a semiconductor chip (die) or package to a substrate (another die, printed circuit board, or the like.
BACKGROUND OF THE INVENTION
Semiconductor technology has shown a general trend towards dramatic increases in integrated circuit speed and density. Both of these trends are facilitated by an overall reduction in device (circuit element) geometries (sizes). As semiconductor circuit elements become smaller, the distances between them on a semiconductor die become smaller, and parasitics (such as parasitic capacitances) and switching currents become smaller. In technologies such as CMOS, where overall current draw and switching speed characteristics are dominated by the effects of parasitics, the result is a reduction in total power consumption at the same time as switching speed is improved. Overall speed is further improved by the reduction in signal propagation time between active devices (e.g., transistors) resulting from the shorter distances involved. Nevertheless, in high speed integrated circuitry based on sub-micron geometries, delays in the tens or hundreds of picoseconds can be appreciable.
In order to minimize the length of wiring between semiconductor devices, a technique generally known as "flip chip" mounting is employed. A number of patents show that a semiconductor die (or "chip") can be "flip-chip" mounted and connected to another die (or "substrate") via a pattern or array of conductive bumps disposed on a surface of a semiconductor die, or on both the die and an underlying substrate. For example U.S. Pat. Nos. 4,825,284 and 4,926,241, incorporated by reference herein, describe methods for "flip-chip" mounting of a semiconductor die to a substrate by means of conductive (solder) bumps. Typically, the conductive bumps are ball-like structures formed of solder and disposed in a pattern on a surface of the die. A mating pattern of bond pads and/or similar conductive bumps is disposed on a surface of the underlying substrate. The die is positioned over the substrate and the conductive bumps on the die are "re-flowed" or otherwise fused to their counterpart connection elements on the surface of the substrate to form both electrical and mechanical connections between the die and the substrate.
Similar techniques are known in the art for mounting a semiconductor device package to a printed circuit board or other substrate, although they tend to be on a larger scale than the techniques for mounting a semiconductor die to a substrate. U.S. Pat. Nos. 4,700,276, 5,006,673, and 5,077,633, incorporated by reference herein, are generally directed to such techniques. Semiconductor devices employing conductive bumps are commonly referred to as "pad array chip carriers", or as "bump grid arrays". Other references to pad array chip carriers and similar mounting techniques are found in "Pad Array Improves Density" (Electronic Packaging and Production, May 1992, p. 25.), "Overmolded Plastic Pad Array Carriers (OMPAC): A Low-Cost, High Interconnect Density IC Packaging Solution for Consumer and Industrial Electronics", (Freyman and Pennisi, IEEE Publication No. 0569-5503/91/0000-176, 1991), and "LED Array Modules by New Technology Microbump Bonding Method" (Hatada, Fujimoto, Ochi, Ishida, IEEE Transactions on Components, Hybrids and Manufacturing Technology, Vol. 13, No. 3, Sep. 1990, pp. 521-527). A related mounting scheme is disclosed in U.S. Pat. No. 4,717,066, incorporated herein by reference, wherein a gold alloy is used for the conductive bumps (balls) rather than solder.
Hereinafter, all conductive bump connection techniques, both for chips (semiconductor dies, e.g., "flip-chip" mounting) and packaged semiconductor devices (e.g., pad array chip carriers) will be referred to collectively as "bump bonding", and the resulting assembly of one element to another will be referred to as a "bump-bonded assembly".
Generally, as used herein, a bump-bonded assembly includes one or more relatively small silicon chips (or packages) mounted in face-to-face relationship to a larger silicon chip, package, or substrate. Solder balls are formed on the opposing faces of the chips (or packages) and the substrate, at a number of positions corresponding to one another. In other words, the pattern and spacing of the solder balls on the chip (or package) match the pattern and spacing of solder balls on the substrate. Generally, for bump bonding semiconductor dies, the conductive bumps are arranged around a peripheral area of the die, although locating bumps in a central area of the die is also possible. The chip (or package) is brought into face-to-face relationship with the substrate, and with the solder balls of the chip (or package) aligned with the solder balls of the substrate. The chip (or package) and substrate are subjected to heat, which (ideally) causes the solder balls of the chip (or package) to fuse with the corresponding solder balls of the substrate, thereby forming solder joints between the chip and the substrate.
When using bump bond technology, there are significant reliability issues associated with the bump breaking in use. It is widely known in the art that conductive bump connections between a die and a substrate may (and often will) break because of differences in rates of thermal expansion between the die and the substrate. Thermally induced mechanical stresses at the conductive bump bonds can build up to a point where the mechanical structure of the conductive bump fails and the bump breaks or is "torn" away from the die.
Although this failure mechanism is well documented, it is by no means the only failure mechanism. Stresses on conductive bumps caused by mechanical shock of moderate values (50-100 g's) can easily exceed the strength of the bump bond connections. In the absence of completely uniform distribution of stress over the array of solder bumps, individual conductive bumps can easily be broken, or torn away from the die, by stresses of this magnitude.
When added to the probability of thermally-induced bump bond failures, the probability of mechanical shock-induced bump bond failures augments the overall problems associated with bump bonding, and makes conventional bump bonding techniques unsuitable for many harsh environments (e.g., many automotive, aircraft and military applications) without some auxiliary means of limiting mechanical shock.
One possible approach to preventing mechanical shock-induced failures of bump bonds is to anchor the die firmly to the substrate in the process of forming bump bond connections, for example, via a die attach structure (e.g., a planar "spacer" between the die and substrate to which both are firmly attached). For example, commonly-owned U.S. Pat. No. 5,111,279, incorporated by reference herein, discloses a preformed planar structure interposed between a chip and a substrate which is formed of materials which will tend to draw the chip towards the substrate. In this manner the die is secured and prevented from converting mechanical shock into shear forces at the bump bond connections. Unfortunately, however, this may exacerbate the problem of alleviating thermally induced stresses within the die itself, and thermal mismatches between the die and the substrate. Since the die is now firmly mounted to the substrate (via the planar spacer), any stresses due to thermal coefficient mismatch are transmitted directly to the die, creating a risk of fracturing the die.
Further, thermal coefficient mismatch with the die attach structure can create additional thermally-induced stress problems. For example, as the die attach structure (interposed between the die and the substrate) is subjected to thermal changes, it may expand at a different rate in the vertical direction (i.e., in the die-to-substrate direction) than the bump bond connections (e.g., solder joints). As a result, the die attach structure can create a situation where the bump bond connections are literally being pulled apart by the thermal expansion of the die attach structure.
The die can be cooled to reduce thermally induced stresses, both at the bump bond connections and within the die itself. Conductive cooling via heat-sink structures can be used, but this approach tends to be bulky and expensive. Many active approaches to cooling are known in the art, including fan-forced gas (e.g., air) cooling whereby a flow of a cooling gas is directed at or around the die. A die attach structure, depending upon the material used, can provide some conductive cooling. However, a die attach structure interposed between the die and the substrate, particularly a planar structure interposed between the die and the substrate, tends to limit gas or fluid-based cooling in the die by preventing gas or fluid flow between the die and the substrate. This can be particularly troublesome in multi-tier stacked flip-chip assemblies where some dies may have very little exposed surface area.
What is needed is a die attach structure, suitable for interposition between a die (e.g., a semiconductor chip or package) and a substrate (e.g., another semiconductor chip or a printed circuit board), which mechanically joins the chip to the substrate without augmenting thermal stress problems of the assembled chip and substrate, and which facilitates cooling of the die.
DISCLOSURE OF THE INVENTION
It is therefore an object of the present invention to provide a improved technique for bump bonding (e.g., flip-chip mounting) of semiconductor dies.
It is a further object of the present invention to provide a bump bonding technique which substantially reduces the probability of mechanical shock-induced failures.
It is a further object of the present invention to accomplish the foregoing objects without adding significantly to the probability of thermal stress-induced failures.
It is a further object of the present invention to provide an improved technique for bump bonding which facilitates cooling of semiconductor dies.
According to the invention, a non-planar die attach structure is interposed between a die and a substrate. The die attach structure is suitably made of a thin sheet of material deformed in two or three dimensions to have a first set of peaks (positive excursions) on one side and a second set of peaks (negative excursions) on an opposite side.
In one embodiment, the die attach structure is rippled, having a "travelling-S" cross section. Vertical peaks extend longitudinally across the structure on both sides of the structure.
In another embodiment, the die attach structure is formed like an egg-crate, exhibiting arrays of peaks on both sides.
In both embodiments, the peaks on one side of the structure are attached (such as with an adhesive) to the die, and the peaks on the other side of the structure are attached to the substrate. The non-planar shape of the die attach structure provides stress-relief for solder bump connections between the die and the substrate. The die attach structure of the present invention is robust to the stresses associated with shock and preferably matches the coefficient of expansion of the solder bumps. The die attach structure is sized to fit within a central area of the die, so that the ball bump connections (e.g., solder joints) can be made outside the periphery of the die attach structure. The peaks on the one side of the die attach structure are coplanar, and the peaks on the opposite side of the die attach structure are also coplanar--the plane of the peaks of the opposite side being vertically offset from the plane of the one side.
In the one embodiment of the invention, the die-attach structure is "rippled" or accordion-shaped (zig-zag folded), and is sized to fit between a die and a substrate (i.e., its area is made somewhat smaller than the outline of the die so that it fits inside of the bump bond connections (which are typically disposed just inside the periphery of the die), and its height is equal to the desired spacing between the die and substrate). In this respect, the height of the die-attach structure defines the ultimate height of solder joints formed between the die and the substrate. The die-attach structure is essentially a "sheet" of material formed in a "rippled" configuration similar to that of corrugated fiberglass or steel. Such rippled shapes are characterized by an overall planar volume, with a cross-section exhibiting a series of positive and negative peaks.
According to an aspect of the invention, the "rippled" shape of the die attach structure can be a sinusoidal, or other curved "travelling-S" shape.
According to another aspect of the invention, the "rippled" shape of the die attach can be a "triangular-wave" or "sawtooth" shape.
If developed in two dimensions (i.e., if the cross-section is kept constant in one direction, see FIGS. 1 and 2, described in greater detail hereinbelow), "channels" (void areas extending in a longitudinal dimension) are formed between the positive (e.g. top) and negative (e.g., bottom) peaks of the die-attach structure. When the die-attach structure is assembled between a die and substrate, gas or fluid can be directed through these longitudinal channels to cool the die.
The die-attach structure is assembled in a central area between a die and a substrate such that the die attaches to the top peaks of the die attach structure and the substrate attaches to the bottom peaks of the die attach structure (or vice-versa). Conductive bump contacts on the die and the substrate mate outside of the central area of the die-attach structure, in a peripheral area of the die. By anchoring the die to the substrate, the die-attach structure protects the conductive bump contacts (bump bonds) from mechanical shock stress and substantially increases the magnitude of the shock required to damage the conductive bump contacts. Additionally, the rippled shape of the die-attach structure exhibits desirable flexibility or "springiness", as compared with conventional (prior-art) planar structures and die attach techniques.
Mismatches can occur between the thermal coefficients of expansion (TCE's) of the die and the die-attach structure. Given identical material choices, however, the mismatch is no greater than that which would be observed with a conventional die attach. In fact, according to the invention, with proper material selection, the TCE mismatch can be greatly reduced.
In matching the vertical coefficient of expansion of the solder bumps to the coefficient of the die attach, it is necessary to select a die-attach material with a coefficient of thermal expansion which exceeds that of the crystal silicon die material. Most metals, including aluminum, copper, and magnesium, meet this requirement.
The matching of the coefficient of expansion of the die-attach structure to the silicon die material is accomplished by controlling the offset of the positive and negative peaks of the die-attach structure. A "die-attach" angle ("Θ") is defined by a line drawn between the positive and negative peaks of the die attach "rippled" shape, and another line drawn across the positive (or negative) peaks. (If the die attach is not angularly symmetrical, i.e., if the angles are different on opposite sides of an attach point, then the "steeper" die-attach angle dominates.) In this manner, the apparent vertical coefficient of expansion is effectively the TCE of die attach material times the die-attach angle Θ.
This effect (of apparent vertical coefficient of expansion) can be used to minimize the mismatch in vertical coefficients of thermal expansion of the die-attach structure and the solder bumps, thereby providing for secure anchoring of the die and protection of the conductive bump contacts from mechanical shock without causing thermally-induced mechanical stresses (in the vertical direction) at the conductive bump contacts.
In the other embodiment of the invention, a three-dimensional egg-crate shaped die attach can be formed which has rows and columns of alternating positive and negative peaks. Open paths exist in egg-crate structures through which cooling gas or fluid can be directed. Whereas these paths were longitudinal, in the rippled die-attach structure, in the egg-crate shaped embodiment the paths will be more sinuous. By virtue of the fully developed three-dimensional structure of the die attach, thermal coefficient mismatches can be accommodated in three dimensions. Generally, the egg-shape embodiment exhibits similar benefits as does the rippled embodiment of the die-attach structure.
By securely anchoring the die, the inventive die-attach structure reinforces the flip-chipped assembly, and absorbs a significant portion of any mechanical shock applied to the assembly, thereby protecting the conductive bump contacts and reducing the probability of shock-induced failures of bump bond connections.
In part due to the flexibility of the rippled die attach and in part due to TCE matching, the inventive die-attach technique does not worsen thermal stresses within the assembly, and with proper selection of materials and shapes, can reduce thermally induced stresses.
"Channels" or paths through the "rippled" (or egg-crate) shape of the die attach permit cooling gas or fluid to be directed through the die-attach structure between the die and the substrate, permitting improved cooling of the die.
Other objects, features and advantages of the invention will become apparent in light of the following description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a "travelling-S" rippled die-attach structure, according to the invention.
FIG. 2 is a view of a "triangular" or "sawtooth" rippled die-attach structure, according to the invention.
FIG. 3 is a cross-sectional view of a semiconductor device assembly including a rippled die-attach structure, according to the invention.
FIG. 4 is a view of a die-attach structure with an egg-crate "texture", according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In order to reduce mechanical shock-induced stresses at the conductive bump connections of a bump bonded semiconductor die, it is necessary to provide some form of stress relief. This is accomplished by using a rippled, or otherwise texturally deformed die-attach structure between the bonding faces of a die and a substrate. The geometry of the die-attach structure is also of benefit vis-a-vis thermal stress failures. Various embodiments of a die-attach structure are contemplated by the present invention. Examples of "rippled" and "egg-crate" shaped die-attach structures are set forth below.
FIG. 1 shows an example of a "rippled" or "travelling-S" die attach structure 100, sized to fit between a die and a substrate (i.e., its area is somewhat smaller than the outline of the die so that it fits inside of the bump bond connections, and its height is selected to establish a desired spacing between the die and the substrate). The die-attach structure 100 is essentially a "sheet" of material formed (by any suitable means) to exhibit a "rippled" shape (cross-section). The "rippled" characteristic shape is clearly seen at an edge 110 of the die-attach structure, where a sinusoidal "travelling-S" shape is evident. This "rippled" shape (or texture) of the die attach 100 is a two-dimensional shape, i.e., it has a constant cross-section in one dimension, and is characterized by top peaks 120 and bottom peaks 130 offset from the top peaks. In use, the top peaks are attached to a surface of a die with a suitable adhesive (such as epoxy), and the bottom peaks are attached to a surface of a substrate with a suitable adhesive (such as epoxy). In this manner, the die-attach structure forms a mechanical joint between the die and the substrate. In use, the die-attach structure is sized to be somewhat smaller than the smaller of the die and the substrate (typically the die is smaller than the substrate), in order that conductive bump contacts on the opposing faces of the die and substrate will form solder joints outside the periphery of the die-attach structure.
The rippled cross-section of the die-attach structure results in longitudinal "channels" being formed between the top peaks 120 and bottom peaks 130. One such channel is indicated generally along the line A--A' extending longitudinally across the die attach 100. When the die-attach structure is assembled between the opposing faces of a die and a substrate, gas or fluid can be directed through these channels to assist in cooling the die, thereby alleviating certain adverse effects of heating.
FIG. 2 shows an alternate embodiment 200 of a "rippled" die attach, similar to the travelling-S die attach 100 of FIG. 1, but having a two-dimensional triangular "sawtooth" shape rather than the sinusoidal (traveling-S) shape shown in FIG. 1. As before, the die attach 200 is sized to fit between a die and a substrate, and is essentially a "sheet" of attach material formed in a "rippled" sawtooth configuration. The triangular sawtooth shape is clearly seen at an edge 210 of the die attach. Similar to the die attach 100 (FIG. 1), the shape of the die attach 200 has top peaks 220 which attach to the die and bottom peaks 230 which attach to the substrate. "Channels" between the top peaks 220 and bottom peaks 230, such as the one indicated generally along the line B--B', extend across the die attach 200, through which gas or fluid can be directed through these channels to cool the die (once assembled).
FIG. 3 is a cross-sectional view of an assembly 300 wherein a die 320 is bump bonded to a substrate 310, using the die-attach structure 100 of FIG. 1. (The die-attach structure 200 of FIG. 2 could be substituted.) The die 320 attaches to the top peaks 120 of the die-attach structure 100 by an adhesive 325 and the substrate 310 attaches to the bottom peaks 130 of the die attach 100 by an adhesive 326. Conductive bump contacts 330 (one shown) electrically connect the die 320 to the substrate 310. By providing a mechanical connection between the die 320 to the substrate 310, the die-attach structure 100 protects the conductive bump contacts 330 (bump bonds) from mechanical shock stress and substantially increases the magnitude of the shock required to damage the conductive bump contacts 330. In addition, the rippled shape of the die-attach structure 100 will exhibit a certain degree of flexibility or "springiness", further alleviating the adverse effects of mechanical shock.
It will be evident to one of ordinary skill in the art that a mismatch can occur between the thermal coefficients of expansion (TCE's) of the die 320 and the die-attach structure 100. (A similar mismatch can occur between the substrate 310 and the die attach 100.) The mismatch, however, will be no greater than that which would otherwise be observed with a conventional die attach (given the same materials). However, according to the present invention, the "rippled" shape of the die-attach structure can exhibit beneficial thermal expansion behavior, especially in the vertical (as depicted in FIG. 3) direction, and the coefficient of expansion of the die-attach structure 100 can be tailored to match the coefficient of expansion of the conductive bump contacts 330, thereby reducing stresses caused by differences in vertical thermal expansion. By appropriate selection of a material for the die-attach structure 100 (which selection will be determined by the particular application for which the die-attach structure is employed), a die-attach structure 100 can be created that simultaneously matches the coefficient of expansion of the conductive bump contacts 330 (for example, solder) and reduces the effect of the coefficient of expansion mismatch between the die 320 and the substrate 310.
In matching the vertical coefficient of expansion of the conductive bump contacts 330 to the coefficient of expansion of the die attach structure 100, the only requirement for selecting the material for the die-attach structure 100 is that its temperature coefficient of expansion exceeds that of the crystal silicon material making up the die 320. This requirement is not difficult to meet, since most metals, including aluminum, copper, and magnesium, have temperature coefficients of expansion greater than crystal silicon.
The apparent vertical coefficient of expansion of the die-attach structure can be controlled by its rippled shape, and matched well to the coefficient of expansion of the die. For the rippled shapes of FIGS. 1 and 2 (or any textured shape exhibiting positive and negative peaks), a die-attach angle Θ is defined as the angle formed by the intersection of a line drawn between a positive peak and the next vertically offset negative peak with a line drawn across the positive (or negative) peaks. In a case where the die-attach structure is asymmetrical, the steeper of two or more angles determined in this manner dominates in the calculation of the apparent vertical thermal coefficient of expansion. The apparent vertical thermal coefficient of expansion is suitably determined as the thermal coefficient of expansion (TCE) of the material of the die-attach structure times the sin of the dominant die-attach angle Θ.
Hence, by proper selection of materials, the actual and apparent thermal coefficients of expansion for the die-attach structure can be tailored to match the thermal coefficients of expansion of both the solder joints of the conductive bump contacts and the silicon die. In this manner, the die-attach structure provides for secure anchoring of the die to the substrate and provides protection from mechanical shock for the conductive bump contacts, without causing thermally-induced mechanical stresses (in the vertical direction) at the conductive bump contacts.
In a conventional prior-art die attach scenario, a TCE mismatch between the substrate and the die can cause thermally-induced stresses to occur which can crack the die or cause it to become detached from the substrate. The "rippled" shape of the die-attach structure of the present invention can be used to accommodate this mismatch in at least two different ways. First, the "rippled" shape has a certain amount of flexibility in at least one dimension (horizontal, as depicted in FIGS. 1 and 2) and can absorb some of the thermal stress. Second, as will be evident to one of ordinary skill in the art, similar thermal coefficient matching between the die and the substrate can be accomplished by controlling the angles between points of attachment of the die and substrate to the die attach, in a manner similar to that described above for matching vertical coefficients of expansion. By proper selection of both die attach material and die attach angle, both vertical and horizontal coefficients will be matched.
It will readily be appreciated by one of ordinary skill in the art that cooling gas or fluid can be directed between the die 320 and the substrate 310 through the channels (e.g., along line A--A', FIG. 1) to improve heat dissipation from the die.
Although the rippled, or two-dimensionally deformed shapes for a die-attach structure provide flexibility in two dimensions (laterally and vertically), they do not provide "flexibility" in the longitudinal direction (i.e., along line A--A' of FIG. 1, or along line B--B' of FIG. 2). In order to achieve flexibility, and similar benefits thereof, in the longitudinal dimension, it is necessary to provide a three-dimension texture to the die-attach structure.
FIG. 4 shows a die-attach structure exhibiting deformations in three-dimensions. An example resembling an egg-crate is illustrated in FIG. 4. The egg-crate shape has rows and columns of alternating positive peaks 420 and negative peaks 430. Further, open paths exist in the egg-crate structures (e.g., along line C--C') through which cooling gas or fluid can be directed. By virtue of the fully developed three-dimensional structure of the die-attach structure 400, thermal coefficient mismatches can be simultaneously accommodated in three dimensions (rather than only two, as was the case with the rippled shapes of FIGS. 1 and 2). In other words, the concepts discussed hereinabove with respect to rippled shapes are simply extended (to the longitudinal dimension) with the three-dimensionally deformed egg-crate (or similar) shape of the die-attach structure 400.
One skilled in the art to which the present invention most nearly pertains will understand that the choice of whether to use the traveling "S" structure, the triangular structure or the fully developed egg crate structure will be made depending upon the magnitude of the mismatch of TCE's of the substrate, conductive bump and die materials, and will vary from application to application.
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A technique for forming bump bonded semiconductor device assemblies is described wherein a die attach structure is disposed between a semiconductor die and a substrate. Bump bonds (conductive bump contacts) are formed between the die and the substrate, outside of the periphery of the die attach structure. The die attach structure has a "rippled" or egg-crate shaped shape or texture characterized by alternating positive and negative peaks. The die is attached (e.g., by an adhesive) to the positive peaks, and the substrate is attached to the negative peaks. The die attach has the effect of anchoring the die to the substrate and absorbing mechanical shocks which would otherwise be transmitted to the conductive bump contacts. This serves to improve the shock resistance of the chip/substrate assembly. The die attach structure can be made to match the coefficient of expansion of the bump bonds as well as that of the die.
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BACKGROUND OF THE INVENTION
A. Field of Invention
This invention pertains to beverage cans as well as containers for foodstuff and other household goods having various images provided on their outside surfaces. More particu- larly, the present invention pertains to containers such as metallic cans, cardboard boxes and the like, which are provided with an electronic display for showing images thereon, including for example, still or moving color images related to the contents of the container, other products made by the same manufacturer, or even unrelated subject matter.
B. Description of the Prior Art
Beverage containers such as cans are typically formed with a cylindrical sidewall and two circular ends made of sheet metal. Typically, the sidewall is provided with a colorful label identifying the manufacturer and the contents of the can. The label is printed on the sidewall of the container itself, or on a paper or plastic sleeve which is then attached to the can. Sometimes, additional information is provided on the ends as well.
A major function of the label on beverage containers is to attract the attention of the customer. The label can be a powerful advertising means which can increase sales and revenues. Therefore, manufacturers compete to make beverage and other containers very colorful and striking to attract as much attention as possible.
OBJECTIVES AND SUMMARY OF THE INVENTION
An objective of the present invention is to provide a beverage container with a display disposed on a container sidewall which can selectively show a plurality of electronic images.
A further objective is to provide a beverage container with an electronic display and associated circuitry capable of showing moving images.
Yet another objective is to provide a beverage container with a display, speakers and circuitry to provide multimedia presentations including still images, moving images and sound.
Other objectives and advantages of the invention will become apparent from the following description of the invention.
Briefly, a beverage container constructed in accordance with this invention includes a tubular sidewall and two end walls cooperating to form a closed, water and airtight enclosure for a liquid. A sleeve is mounted around the tubular wall. The sleeve includes a display arranged to show images, including color images, in response to electrical signals generated by a control circuit. The control circuit is mounted on the beverage container as well and includes a memory storing imaging data, a microprocessor and a driver receiving commands from the microprocessor and generating the electrical signals for the display. The control circuit further includes sensors coupled to the microprocessor for sensing a predetermined condition. These sensors include a manual switch and/or other elements which detect ambient light or the opening of the container. The microprocessor is responsive to signals from the sensors and activates the display or modifies the images on the display in some manner. A battery is also provided for powering the control circuit and the display.
Optionally, small speakers may also be provided on the container.
The control circuit is adapted to generate on the display still images or moving images, or, if provided with speakers, may provide a multimedia presentation combining the images with sounds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a beverage container with a sleeve having a display constructed in accordance with this invention;
FIG. 2 shows a developed view of the sleeve of FIG. 1;
FIG. 3 shows a cross-sectional view of the sleeve of FIGS. 1 and 2;
FIG. 4 shows a block diagram of the control circuit associated with the display incorporated into the sleeve shown in FIGS. 1-3; and
FIG. 5 shows a flow chart for showing several (for example, three) visual and/or multi-media presentations using the display and its circuitry shown in FIGS. 1-4.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-4, a beverage container 10 constructed in accordance with this invention consists of a body 12 having a cylindrical sidewall 14, a top end wall 16 and a bottom end wall 18. The bottom end wall 18 is usually bowed inwardly leaving a concave space under the container 10. Disposed around the sidewall 14 is a sleeve 20.
As shown in FIG. 2, the sleeve 20 has two ends 22, 24 which are joined seamlessly when slipped over body 12. A display 26 is formed on the sleeve 20. Preferably the display 26 is made of a flexible material such as light emitting polymer (LEP) available from Cambridge Display Technology of Cambridge, U.K. Between display 26 and one end 22, the sleeve 20 may be provided with a zone 28. This zone (as well as a zone adjacent to end 24, not shown) may be reserved for standard printed matter containing the identification of the manufacturer, the contents of the container 10 and so on. This printed matter is provided in case the display 26 fails. Alternatively, the display 26 may extend continuously all around the body 12 and the printed matter may be provided on either the top wall 16 or the bottom wall 18.
As shown in FIG. 3, the display 26 is preferably composed of three layers: a plastic base 32 which is used to provide strength and dimensional stability to the sleeve 20, the LEP layer 34 (including the associated drive conductors), and a protective layer 36. The protective layer 36 is also made of a plastic material and is transparent or at least translucent so that the images formed by the LEP are clearly visible.
A control circuit together with a battery is incorporated into a case 38 disposed, for instance, in the space formed by the bottom wall 18, or on top wall 16 as shown in FIG. 1 at 38'.
Referring now to FIG. 4, the control circuit 42 includes a microprocessor 44, a memory 46 and a display driver 48. The memory 46 is used to store digital data for various images. The microprocessor 44 retrieves this data and uses the same to generate commands to the display driver 48. The display driver 48 generates electrical signals in response to the commands from the microprocessor 44. These electrical signals are sent to display 26. Power to the control circuit 42 is provided by a battery 52.
Also associated with the control circuit 42 are three sensors 52, 54, 56. These sensors detect when certain predetermined conditions exist as described below.
When the container 10 is disposed in a closed box for shipping, or inside a refrigerator, there is no need for any images to be generated and accordingly the display may be turned off to save energy thereby extending the life of battery 50. Sensor 52 comprises a light detector. As soon as it detects light, it sends a corresponding signal to microprocessor 44. The microprocessor 44 is then primed to show images on the display 26 as discussed more fully below.
As seen in FIG. 1, top wall 16 of container 10 is provided with a closing tab 40. This tab 40 is removed or lifted by a customer to open the container 10. If the container 10 is pressurized, for example, if it holds beer or soda, its body 12 undergoes a slight distortion when the tab 40 is opened. Sensor 54 could be a stress sensor (for example, a piezoelectric transducer) which detects a flexure of body 12. Alternatively, the sensor 54 may be a standard miniature switch which senses when tab 40 is opened or removed. In response to the opening of the tab 40, the sensor 54 sends a corresponding signal to the microprocessor 44.
Sensor 56 may comprise an activating switch 56A such as a mechanical switch which may be selectively activated by a customer. The switch 56A may be attached to the sleeve 20, as shown in FIGS. 1 and 2. Alternatively, the sensor 56 may be a touch sensitive sensor embedded into the sleeve which is activated when a customer lifts the container. For example, the touch sensitive sensor may overlap the zone 28 shown in FIG. 2.
Finally, the container 10 may also be provided with several piezoelectric or ceramic speakers 58. These speakers 58 may be disposed on the sleeve 20 and/or on the top wall 16 as shown. Alternatively, the speakers may be provided in the form of a sheath (not shown) incorporated into sleeve 20.
The display 26 comprises a number of pixel elements depending, for example, on the size of the container 10. Even for a large container, a display of 480×640 pixels may be sufficient. If memory 46 has a storage capacity of 10 M bytes, and if data compression is used, it can hold data for up to five hundred color images for the display 26. Alternatively, instead of pixels, the display 26 may comprise several discrete image elements having distinct shapes, the image elements being selectively activated by the microprocessor 44. The images can be shown one at a time, or may be displayed in a rapid succession to generate moving images. These moving images may be accompanied by appropriate sounds from the speaker 58.
A typical operation for a container 10 is now described in conjunction with FIG. 5. In this Figure, initially, the control circuit 42 is in an idle mode (step 100). In this mode the light sensor 52 is monitored (step 102). If light is sensed, it is assumed that the container has been placed on a shelf in a store and accordingly, a preselected presentation A, consisting, for example, of a plurality of images shown in succession is started in step 104. In step 106 the presentation A continues to be played until one of several events take place. Alternatively, presentations may be delayed until one of these events occurs.
In step 108 a check is performed to determine if sensor 56 has been activated, by a customer or potential customer. For example, adjacent to switch 56A, a sign (which may be presented by display 26 at 60) may be provided with the legend `PRESS HERE TO GET MORE INFORMATION.` If the sensor 56 is a touch sensitive switch, it is automatically activated when the container is lifted, as discussed above.
Returning to FIG. 5, in step 108, if the sensor 56 is activated then in step 110 the data for a second presentation B is retrieved from the memory 46 and is shown in step 112 on display 26. Presentation B may provide further information about the beverage in container 10. Alternatively, in response to the activation of sensor 56, a different unrelated presentation may be shown. For example, the legend may indicate that a presentation is available regarding a coming movie attraction. At the end of presentation B, the system recycles to step 100.
If in step 108 it is determined that sensor 56 has not been activated, then in step 114 a check is performed to determine if sensor 54 has been activated, indicating that the container 10 has been opened. If in step 114 the sensor 54 has been activated, then in step 116 the data for a third presentation C is retrieved from the memory 46 and shown by display 26 in step 118. This third presentation C may be related to other products made by the same company or promotional data informing the customer of prizes, goods or services associated with the sale of the container 10. Alternatively, the third presentation C may concern an unrelated product or service. At the end of the third presentation C, the system may recycle to step 100. Some, or all the presentations A, B, and C may be multimedia presentations consisting of still or moving images combined with sounds emitted from speakers 58.
If in step 114 it is determined that sensor 54 has not been activated then the system returns to step 106 and continues displaying the first presentation A.
The mode of operation described in FIG. 5 is presented merely as an illustration of the flexibility of the system. The number of presentations, their content and length is limited only by the information storage capability of the memory 46. Obviously many different types of presentations and modes of operations can be stored and sequenced as well. Moreover, other types of sensors may be added and some or all of the sensors 52, 54, 56 may be omitted.
The subject invention has been described in association with a beverage container. One skilled in the art will appreciate that with little or no modification the invention may also be used to show still pictures, moving pictures, or multimedia presentations on various other types of containers as well, such as plastic or glass bottles, cardboard or plastic boxes and other containers used for packaging and dispensing various foods, or other household products.
Numerous modifications may be made to the subject invention without departing from its scope. The present embodiments are therefore to be considered in all aspects as illustrative and not restrictive in any manner.
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A container for a beverage or other foods or household goods includes a wall with a display generating digital images. A controller is also provided associated with a memory, said memory storing digital imaging data. The controller selectively retrieves the data from the memory and generates electrical signals to the display. Switches, sensors and other selector elements may be provided to activate the display and to select the images to be shown. Additionally miniature speakers may also be provided which cooperate with the display to show multimedia presentations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns a shelf for the supportive positioning of objects placed thereupon, and more particularly relates to a shelf which can be adjustably positioned at different elevations upon a vertical post.
2. Description of the Prior Art
Shelves designed for holding or storing objects are generally characterized in having a flat horizontal upwardly facing surface and support means which secure the position of the shelf. Numerous shelving systems have been disclosed comprised of shelves and support means permitting adjustable mounting upon a wall at different elevations.
The adjustable positioning of trays, shelves and baskets upon a vertical support post is disclosed in U.S. Pat. Nos. 494,758; 3,414,133; 5,144,023; D324,148; D325,838; and elsewhere. Such devices either require that the post penetrates a mounting aperture in the shelf surface, or require modification of the post, or are adapted for use only on a post of a particular shape and size, or involve extensive manipulation and/or use of tools to achieve positional adjustment.
Outdoor recreational areas are often located behind private dwellings, and may be bordered at least in part by a fence or railing that affords privacy, enhances decor, or serves still other purposes. Fences are often comprised of a series of vertical posts. In such situation, it would be desirable to utilize the posts to support shelves that can hold food and beverage items, game devices, reading material, garden utensils, plants, or other things encountered in the general course of using such "backyard" areas. Other vertical post structures besides fence posts may also be found in backyards, such posts being employed for example for bird feeders, recreational equipment, floodlights, antennas and other purposes.
It is accordingly an object of the present invention to provide a shelf device supportable by a vertical post at easily adjustable elevations.
It is another object of this invention to provide a device as in the foregoing object which does not require tools or modification of said post to be supported thereby.
It is a further object of the present invention to provide a shelf device of the aforesaid nature of simple, rugged construction amenable to low cost manufacture.
These objects and other objects and advantages of the invention will be apparent from the following description.
SUMMARY OF THE INVENTION
The above and other beneficial objects and advantages are accomplished in accordance with the present invention by a shelf device which adjustably attaches to a vertical post at variable elevations, said shelf comprising:
a) a mounting base comprising a panel elongated between forward and rearward extremities and having a horizontally disposed upper abutment edge and flat interior and exterior sidewalls,
b) post-engaging abutment means disposed upon said interior sidewall adjacent said rearward extremity,
c) laterally adjustable gripping means interactively associated with said post-engaging abutment means,
d) a support arm pivotably attached to said sidewall and bounded by front and back extremities, upper and lower border surfaces, and interior and exterior side faces, said interior side face being flat and adapted to slideably contact the interior sidewall of said mounting base, said back extremity having a vertical portion adjacent said lower border surface, and an upper portion recessed forwardly toward said front extremity,
e) horizontally adjustable stop means protruding rearwardly from the vertical portion of said back extremity and positioned to press against a post intervening between said post-engaging abutment means and the back extremity of said support arm, and
f) a shelf member horizontally disposed upon the upper border surface of said support arm.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawing forming a part of this specification and in which similar numerals of reference indicate corresponding parts in all the figures of the drawing:
FIG. 1 is a top plan view of an embodiment of the device of this invention.
FIG. 2 is a side view taken from the left of FIG. 1.
FIG. 3 is a side view taken from the right of FIG. 1, showing two positions of the shelf.
FIG. 4 is a front view of the embodiment of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-4, an embodiment of the adjustable height shelf device 10 of this invention fabricated substantially entirely of wood is shown in functional association with a vertical post 11 of rectangular contour.
The shelf device is comprised in general of a mounting base 12, a support arm 13 attached to said mounting base, and a shelf member 14 disposed upon said support arm.
Said mounting base 12 is comprised of a vertically oriented panel 15 elongated between forward and rearward extremities 16 and 17, respectively, and having a horizontally disposed upper abutment edge 18, and flat interior and exterior sidewalls, 19 and 20, respectively.
Post-engaging abutment means in the form of straight vertical rail 21 is disposed upon said interior sidewall adjacent rearward extremity 17 of said mounting base. In alternative embodiments, said post-engaging abutment means may be integral with panel 15, as when the components of the device are fabricated of plastic.
Laterally adjustable gripping means in the form of elongated bracket 22 is associated with rail 21 by way of threaded bolt 23 and paired parallel alignment rods 24 which extend horizontally from rail 21 into receiving bores 25 in bracket 22. A knurled flat-shouldered nut 26 threadably disposed upon bolt 23 enables bracket 22 to be urged toward panel 15. A forwardly disposed retaining lip 27, integral with bracket 22, is configured to press the intervening vertical post 11 against interior sidewall 19.
Support arm 13 is attached by way of pivot means in the form of screw 28 to panel 15 at a site closer to rearward extremity 17 than foreward extremity 16. Support arm 13 is bounded by front and back extremities, 29 and 30, respectively, upper and lower border surfaces 31 and 32, respectively, and interior and exterior side faces, 33 and 34, respectively. Said interior side face 33 is flat and adapted to slidably contact the interior sidewall 19 of panel 15. Back extremity 30 has a vertically oriented portion 35 adjacent lower border surface 32, and has an upper portion 36 which is recessed forwardly toward front extremity 29. Although the manner of such recess is exemplified as a straight angled or chamfered corner region, such recess may be of curvilinear or multi-faceted contour. The recess may be further characterized as a deleted portion of the support arm which would otherwise be present at the intersection of a continuation of vertically oriented portion 35 and upper border surface 31.
Horizontally adjustable stop means in the form of plug 37 protrudes rearwardly from vertically oriented portion 35 and is threadably associated with arm 13 in a manner to press against vertical post 11 when arm 13 is in its lowermost position of travel, as shown in FIGS. 1, 2 and 3.
Shelf member 14 is secured as by bolting or adhesives to the upper border surface 31 of arm 13. When the support arm is in its lowermost position of travel, the underside of shelf member 14 rests upon the upper abutment edge 18 of panel 15. Although the exemplified embodiment of the shelf member has a polygonal perimeters other configurations may be employed.
In applying the device of this invention to a vertical post, support arm 13 is raised by pivotal motion with respect to panel 15. In such position, a relatively large space, denoted by A in FIG. 3 exits between vertical abutment rail 21 and support arm 13. Such position enables the device to easily accommodate a vertical post within space A. It is to be noted that the effectiveness of space A is achievable because the rear edge 39 of shelf member 14 is forwardly displaced from upper portion 36 of back extremity 30. When support arm 13 is lowered, the space, denoted by B in FIG. 3, is smaller than space A. In fact, plug 37 contacts vertical post 11 in said lower position of said support arm. In said lower position, which represents the use position of the device wherein shelf member 14 is horizontally disposed, bracket 22 is caused to tightly engage the side of the vertical post and plug 37 engages the front of the vertical post. The dual mode of securement causes the device to be stable at any chosen elevation upon the post.
In alternative embodiments of the invention, the shelf member may be comprised of just the upper border surface 31 of said support arm. Although of narrow configuration, such embodiment may serve to support an elongated shelf extending between two of the devices of this invention positioned at the same elevation. In a still further object of this invention the shelf member, in the form of said upper border surface may be forwardly elongated and may serve to support a pendently disposed structure such as a bird feeder, flower pot, candle, wind chimes or other items of outdoor use.
While particular examples of the present invention have been shown and described, it is apparent that changes and modifications may be made therein without departing from the invention in its broadest aspects. The aim of the appended claims, therefore, is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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A device for the supportive positioning of objects at different elevations along a vertical post includes a shelf member disposed upon a support arm pivotably secured to a mounting base. Post-engaging brackets are associated with the mounting base, and interact with an adjustable stop protrusion on the support arm to grip an intervening fencepost when the support arm is swung to its lowermost position.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0003] Not Applicable
FIELD OF THE INVENTION
[0004] The invention relates to the field of wearable sensor devices attached to an animal, including human, body and signaling certain conditions for detection by observers like humans or a camera integrated computer such as in a contemporary ‘smartphone’.
BACKGROUND OF THE INVENTION
[0005] The monitoring of fever episodes is the main use of the current invention. To get core body temperature is very difficult unless you use a probe that is inserted to body cavities. This is good if you only need to monitor temperature once in a while. There are temperature changing stickers that you can use. It is not all that accurate and you need to keep watching it to know what is going on and visibility is poor at night. Skin temperature is usually dependent on sweating, air temperature, body temperature, blood circulation, body extremities and other parameters. So typical sensors on skin is not a good indicator of core body temperature.
[0006] Body temperature rise from exertion is not normally taken care of in a normal electronic or chemical temperature sensors. This adds another layer of error in the reading.
[0007] Typical electronic monitoring thermometers suffer from battery capacity when transmitting temperature continuously over wireless networks making them bulky or having to recharge them often.
BRIEF SUMMARY OF THE INVENTION
[0008] The apparatus and method disclosed is based on the idea of detecting temperature changes and not absolute temperature. This allows the use of skin temperature as a gauge for core temperature variation. This can be used to generate alarms in certain situations. For example, your child is still sick with 102 degree F. (measured with a body cavity thermometer) viral fever at 10 pm. You just gave him fever-reducing medicine. You do not typically know if the child's fever is still high or lower from that time to the time for next dose which is typically 4-6 hours from 10 pm. The only way around it is you do not sleep, wake the child up from time to time and measure temperature. If the temperature is still rising, you need to give him medication earlier, apply cold head patches or even take the child to emergency hospital to prevent brain damage.
[0009] To allow for skin temperature variation to be used as a proxy for core body temperature, it needs to be used in the head, chest or back areas. Care is taken to isolate the sensor from the environment and trap the heat in an air pocket where the sensor is situated. It is also based on the idea that the sensor is in the form of an adhesive patch that attaches to the body, is removable and re-usable after adhesive change. An accelerometer is used to detect activity and correct for temperature errors due to exertion. The battery can also be replaced when needed. The temperature change is also communicated to observers, human or computer with camera, by LED's and Audio output. This allows the observer to see the LED status or hear the alarm sounds depending on temperature change magnitude.
[0010] A software running on a contemporary smartphone with a camera is able to detect the change in LED colors and rate of flashing to determine temperature change. This may also be achieved using audio signaling or light signaling. These methods can be used to send temperature and acceleration data to the smartphone software. The software on the smartphone can then call another phone or ring out the alarm or send messages. Another way to send data is using the 3-wire serial port on the sensor patch. This is used to physically be connected to the Bluetooth adapter to transfer data logged in the sensor patch non-volatile memory to the smartphone.
[0011] The accelerometer on the sensor patch can be used as a standalone activity tracker too. Since the sensor patch can be used on the back or chest, they can be easily used as a better sleep detector than the ones on the market that needs lot of data processing to determine sleep condition or pressing a button when you go to sleep. Similarly the sensor patch on the thigh can detect and track sitting detection very well to provide sitting monitoring as this effects the health a lot. This is not available in wrist worn devices like Jawbone wrist band or Mobile phone activity sensor. A typical wrist based sensor like the one described in prior art, Fitbit US Patent Application Publication Pub. No. US2014/0088922A1, the acceleration sensor is worn on the wrist and does not have any unique axis at or near full scale acceleration due to gravity in sleeping or sitting or walking movements. Consequently you need user input to signal sleep or significant processing algorithm to detect activities. This leads to often incorrect data. The sensor patch provides a way to position itself for optimum activity detection.
[0012] In summary these are the unique parts of this invention:
[0013] a unique temperature difference based fever monitoring and alarm;
[0014] a unique positioning and sealing of the flexible temperature sensor package and the skin area related;
[0015] re-usable sensor package with adhesive pad change and coin cell change;
[0016] the sensor package can be attached to different parts of the body for appropriate activity detection. Attach to calf for running detection for example;
[0017] accelerometer based temperature correction for activity related temperature rise;
[0018] calorie expenditure calculation during exercise;
[0019] direct visibility of LED warning signals and audio alarm;
[0020] ideal fever and antipyretic medicine temperature cycle monitoring; extended battery life due to deep sleep mode and lack of a bluetooth or radio wireless device on board;
[0021] unique powered bluetooth module with its own power and connected to sensor package only when data is download without reducing sensor battery life;
[0022] unique software to pair to a computer such as contemporary smartphone using LED color signaling. The software can also work with existing non-electronic temperature sensor strips that change color with temperature;
[0023] unique software to pair to a computer such as contemporary smartphone using audio FSK signaling.
[0024] ability to track basal temperature in the morning just before waking up to monitor conditions like hyperthyroidism based on accelerometer sleep detection and temperature change data logged to memory.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0025] FIG. 1A shows internals of one embodiment of the invention, where 100 is the sensor package that can be attached to the human body or clothing. 110 is the acceleration and gyroscopic sensor integrated circuit packages. 120 is a temperature sensor that sends the temperature of the sensor as an analog voltage output to the analog to digital converter (ADC) of the microcontroller 130 for temperature measurement. 140 represent power source, which in this embodiment is a 3v coin cell. 150 is the Non-Volatile data storage area and 160 the software area within the microcontroller 130 . 170 is an audio output buzzer. 180 is the array of color LED's. Both the LED's 180 and buzzer 170 are used to signal temperature conditions and data communication with smartphones.
[0026] The FIGS. 1B , IC and 10 shows different places on the body where the temperature sensor package 100 may be placed. Position in FIG. 1D is suitable only for monitoring how much sitting and actual walk the user gets.
[0027] FIG. 2A shows the top view of an embodiment of the complete sensor package. Item 200 is the coin cell holder. Item 210 is the mechanical switch. 220 represents the color LED array. 230 represents the microcontroller. 240 shows the buzzer.
[0028] FIG. 2B shows the side view of the sensor package. 280 shows the transparent RTV filled area. 290 shows the pcb assembly. 270 shows the disposable adhesive layer that can be replaced for re-use of the rest of the package
[0029] FIG. 2C shows the bottom side of the sensor package. 250 shows the temperature sensor position and 260 shows the air pocket it forms with the skin to preserve heat for the temperature sensor. 270 shows the disposable adhesive layer that can be replaced for re-use of the rest of the package
[0030] FIG. 3 shows the use of a bluetooth adapter 304 to collect stored data from the sensor 300 detached from the body and its copper strip edge 302 is inserted to the connector 303 on the adapter 304 . Switch 301 is used in a timed hold down to start data download. The data is put out by the sensor 300 through its serial port in 302 and the adapter 304 transmits that data wirelessly to a computer device 305 it is authorized to connect to.
DETAILED DESCRIPTION OF THE INVENTION
[0031] While the making and using of various embodiments of the present disclosure are discussed in detail below, it should be appreciated that the present disclosure provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The disclosure is primarily described and illustrated hereinafter in conjunction with various embodiments of the presently-described systems and methods. The specific embodiments discussed herein are, however, merely illustrative of specific ways to make and use the disclosure and do not limit the scope of the disclosure.
[0032] Conceptual block diagram in FIG. 1A shows one embodiment of the internals of the sensor package. It has a temperature sensor Integrated circuit (IC) 120 that works well in the temperature range of animal body temperature range. It also has an accelerometer IC with 3 axis sensing and a gyroscope for rotation sensing 110 . A low-cost microcontroller 130 is the heart of the system. It has reserved some space in the flash memory for non-volatile memory 150 . Some of the memory is used by the software (firmware) 160 instead. There are three LED's 180 in this embodiment, green, red and yellow. There is also a 170 buzzer on the board. FIG. 2A show flexible printed circuit assembly top view, an embodiment of the invention as built for test. FIG. 2B shows a side view of the sensor package assembly of FIG. 2A . FIG. 2C shows the bottom side of the sensor package of FIG. 2A .
[0033] The microcontroller 230 puts the sensor assembly of FIG. 2A to deep sleep most of the time. When the user pushes the switch key 210 , the microcontroller 230 is interrupted and wakes up and monitors the switch press count with a periodicity of 200 mS. If the switch continues to be pressed and then released during a majority of 10 such 200 mS interrupts, a ‘turn on’ condition is detected. Typically the user would place the sensor package on a kid's forehead and then ‘turn ‘on’ the sensor. Similarly this 200 mS timer is used to detect 5 s and 10 second button presses. The 10 second key press 210 is seen as a signal to upload data from the sensor package of FIG. 2A . A 5 second key press 210 and release is seen as deep sleep condition with long battery life in lieu of actual turn off of the device.
[0034] As soon as it is ‘turned on’, the microcontroller 230 reads the temperature from sensor 250 as analog data input on the microcontroller 230 analog input. The microcontroller 230 wakes up on a periodic timer every minute and takes a reading for the next 5 minutes. The average of these 5 reading is taken as a ‘reference temperature’ reading and is stored in flash data memory as such. The microcontroller 230 then enters its deep sleep mode to save power.
[0035] Once ‘reference temperature’ is taken, the microcontroller 230 wakes up every minute. The microcontroller 230 acquires a new temperature reading. The default yellow LED 180 flashes at 1 Hz rate a couple of times. This reading is compared against the reference every single time this happens. In this embodiment the temperature change limits are considered ±0.25° C., ±0.50° C., ±0.75° C. and ±1.00° C.
[0036] If the [new temperature−reference temperature>0 and within ±0.25° C.] the yellow LED 180 flashes at 2 Hz a couple of times.
[0037] If the [new temperature−reference temperature>0.25° C. and <0.50° C.] the red LED 180 flashes at 1 Hz a couple of times.
[0038] If the [new temperature−reference temperature>0.50° C. and <0.75° C.] the red LED flashes at 2 Hz a couple of times.
[0039] If the [new temperature−reference temperature>0.75° C.] the red LED flashes at 3 Hz a couple of times. The buzzer is turned on for 15 seconds.
[0040] If the [new temperature−reference temperature<−0.25 and >−0.50] the green LED 180 flashes at 1 Hz rate.
[0041] If the [new temperature−reference temperature<−0.50] the green LED flashes at 2 Hz rate.
[0000] The microcontroller 230 also reads the position of the four accelerometer 110 axes using an I2C interface. The microcontroller 230 stores the data current temperature and accelerometer data in the microcontroller non-volatile data memory.
[0042] As described in section [0018] an upload signal from key 210 press of 10 seconds starts the download operation. The sensor package basically transmits the reference temperature data, temperature and accelerometer data paired according to the order they were saved in the non-volatile memory. This signal is transmitted via the UART Rx, Tx and Gnd lines as shown in connector 302 of FIG. 3 . The UART to bluetooth adapter 304 has a connector 303 that will accept the sensor package 301 , connector 302 .
[0043] In another embodiment of the invention, there is no need for a bluetooth adapter to transfer data to a computer device 305 . The software running on the sensor package codes the data to be transmitted during temperature and accelerometer data collection timer events or during upload of entire logged data, into color coded LED colors. The number of bits in each word will depend on the number of LED's 180 available on the device. The color coded data is set on the LED's for a word for a 20 mS, then blanked for the next 13 mS. Then the next word to be transmitted is loaded to the LED's 180 and the process continues till all data is sent. The software running on 305 wakes up when the sensor package LED's are ready to be sent, except the for the first time when the camera and software on the computer device has to be on all the time. Other times, these parts can be sent to low power mode. The said software then opens the camera and captures images at a rate of 30 fps. The images are processed with opencv computer vision library to detect edges of the boundaries (contour) of individual LED's. Then each of the contour area is checked for validity to LED contour sizes and typical LED contour shapes. Then the color of each contour is determined using opencv library functions. Once a whole frame is processed we have reconstructed a word. This is written to a file and the frame is discarded to save memory. This is continued to the end of the data and the said file on device 305 will now have the data transmitted from the sensor package 300 to the computer device 305 . The same image processing technique is used to generate alarms and calls to other phones in case of a particular alarm temperature condition. The above described technique is particularly attractive when sending small amounts of data wirelessly.
[0044] In another embodiment, the software running on a computing device 305 like a smartphone or tablet or a computer device can use its camera or USB camera to detect non-electronic type temperature color-changing stickers and their color change to generate alarms or calls to alert parents.
[0045] In another embodiment of the invention the data transfer between the sensor package 300 and the computer device is through the buzzer audio output. The data to be transmitted from sensor package 300 is coded in frequency shift keying (FSK)modulation and the software running on the smartphone 305 constantly computes the FFT or Goertzel algorithm to detect the signal frequency coming in and converts the bit frames to data. The data is used for further processing for alarm generation or calorie expenditure calculation or activity monitoring.
[0046] Once the computer 305 has uploaded the accelerometer data and temperature data it can correct for body temperature rise due to fever from error due to body temperature rise due to activity. The calorie expenditure is calculated from the temperature difference before exercise and temperature measured after exercise and local environmental temperature from weather server. The acceleration data is used to determine activity and position to determine the correctness of temperature based measurement. The duration and intensity of the activity from accelerometer data is used to calculate approximate calorie expenditure during the period.
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Absolute body temperature measurement is not easy to obtain. The temperature probe has to be placed in body cavities or swallowed to get core body temperature. The skin temperature usually has no relation to core temperature making it impossible to use in wearable devices. The present invention measures body temperature differences to monitor body temperature changes due to fever to generate alarms if needed. The invention is also useful in monitoring body temperature change due to exercise, that can be used to calculate the calories burned during the exercise session, activity and sleep.
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BACKGROUND OF THE INVENTION
This invention relates to a water equilibrating arrangement in a sea-going vessel or the like.
If a sea-going vessel is provided with two side by side compartments, each of which may, in case of damage to the vessel, be filled with water, safety regulations require that water flowing into one of the compartments must also have access to the other compartment. This ensures that the water load will be uniformly distributed over the cross-section of the vessel. If this does not apply, the vessel could lose its stability and capsize.
There is no difficulty in designing compartments which allow water to flow from one compartment to another. However, there is also a requirement for certain compartments to be closed off in a gas-tight manner, for example in case of fire. Closing a compartment prevents the spread of fire and also allows the closed compartment to be filled with gas to choke the fire.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a structure which not only allows large masses of water to flow from one compartment to another, but also makes it possible to prevent the spread of fire or gas from one compartment to another through passages provided for water flow.
In the description and the following claims, the terms "closed" and "closeable" used in relation to a compartment mean that the compartment is closed or may be closed in a sidewards direction. This does not exclude the possibility that the compartment is open upwards through possibly closeable air ducts or the like.
The present safety regulations require that, in case of damage to a vessel, a water mass flowing into one compartment should "instantaneously" provide an equilibrating action in a neighboring compartment. This means that if the equilibrating system were disabled and one compartment was filled with water to the highest level feasible, i.e. to the water level outside the ship, and the equilibrating system was then rendered operative, the equilibrating action must take place within a certain maximum time, for example 60 seconds. The value of 60 seconds is the standard for the present day application of the safety regulations. However, in different applications, the interpretation of the regulations may be different and furthermore the interpretation of these regulations may change in the future. Therefore, it will be appreciated that the value of 60 seconds is only a present day guideline which may change in the future.
In a water equilibrating arrangement according to the invention there is a flow trap between the two compartments. This trap has the same function as the liquid seal (or odor seal) of a sanitary installation. The trap does not normally have to function as a liquid seal, but there must be means provided or arranged to rapidly fill the trap with water or another suitable flowable material to seal the trap in a gas tight manner. An alternative flowable material may, for example, comprise foam material, e.g. a fire extinguishing foam, a gelatinous substance or a substance which, in a filling phase, flows relatively easily but, after a short time, for example due to heat, becomes gelatinous. A granular substance could also be used if it could rapidly fill or block the trap and provide sufficiently good gas tightness. It is only important that the trap can be filled sufficiently rapidly and that an acceptable gas tightness and/or a fire prevention function is achieved when the trap has been so filled.
The trap may advantageously comprise a trough, for example running in the direction of a partition, in particular a bulkhead or the like structure, between the compartments. Such a partition suitably extends downwardly into the trough along the length of the latter, with the trough opening into the two compartments on opposite sides of the partition. The bottom of the trough may conveniently be spaced at a distance from the lower edge of the partition so that a U-shaped flow duct is formed which passes around the lower portion of the partition. Such a structure takes up relatively little space and, being situated at the position of a partition, preferably a bulkhead or the like, between the compartments does not normally obstruct the mounting or use of any machinery or any device and does not substantially restrict the free space available within the compartments, for example for the installation of machinery.
The trap may be totally or to a considerable extent below the floor level of the compartments where there normally is sufficient space available. If there is not sufficient space below the floor level, the trap must be placed at least partly above the floor level. The effect of the position of the trap on the speed of the equilibrating action must be taken into account when dimensioning the trap.
The trap may, in its longitudinal direction, that is in the direction of any partition or bulkhead, be divided into several portions by transverse walls. In this case, changes in the trim of the vessel do not have any significant effect on the functioning of the trap as a liquid seal provided that the distance between the transverse walls is small enough. Transverse walls may also be utilized to improve the rigidity and stiffness of the trap structure and any structures attached thereto.
It is recommended to design the trap so that, when filled with liquid or other flowable medium, the trap is able to prevent through flow of gas between the compartments when the vessel has a heeling angle of at least 5°, preferably up to at least 10°. Such a trap is designed to function in the event of a possible cargo shift or other accident which would be likely to cause heelings of these magnitudes.
It is of advantage that the size of the cross-sectional area of a flow duct of the trap is at least substantially uniform at all flow positions through the trap between the compartments. This is favorable from the point of view of flow dynamics, because it eliminates flow speed fluctuations in the duct. Other arrangements are also possible. For instance if the cross-section of the trap is rectangular, the trap is relatively easy to manufacture and to fit into the other structures of the hull of the vessel.
The floor area available in the compartments in question may be enlarged by covering the opposite ends of the trap which open into the adjacent compartments, with grating structures. The ends of the trap should be so dimensioned that the total area of the grating openings of each grating structure is approximately equal to the smallest cross-sectional area of a flow duct of the trap. Dimensioned in this way the grating structures do not substantially slow down water flow between the compartments during a water equilibrating action.
If storage of a liquid of other flowable medium is provided at a level above the trap, the trap can be rapidly filled with an amount of the liquid or other flowable material sufficient to provide a gas-tight seal of the trap. If it is required to speed up the flow of the liquid or other flowable material into the trap, it is possible to make use of pressurized air, a pump, a compressor or some other suitable device for speeding up the flow of the stored substance. Water for filling up the trap may be taken, for instance, from the sea, from a pool, from a ballast tank or the like.
Means may also be provided for filling the compartments with a fire choking gas or with a corresponding fire preventing substance to improve the fire safety of the vessel. Such means are especially required in engine rooms.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described, by way of example only, with particular reference to the accompanying drawings, in which:
FIG. 1 schematically shows a water equilibrating arrangement according to the invention applied to the engine room of a marine vessel,
FIG. 2 schematically illustrates the functioning of the arrangement shown in FIG. 1 in the event of an accident,
FIG. 3 schematically illustrates the functioning of the arrangement shown in FIG. 1 in the event of a fire,
FIG. 4 is section taken on the line IV--IV of FIG. 1, and
FIG. 5 schematically illustrates a modified form of the water equilibrating arrangement shown in FIGS. 1-4.
DETAILED DESCRIPTION
In the drawings, reference numeral 1 designates a floating vessel, e.g. a marine vessel, having a hull with two sides. The hull contains an engine room which is divided by a longitudinal partition in the form of a longitudinal bulkhead 2 into two closeable compartments 3a and 3b having a floor 4. The two compartments are at opposite sides of a central longitudinal plane of the vessel. One main engine 5 of the vessel is located in compartment 3a and another main engine (not shown so as to make the water equilibrating arrangement according to the invention more clearly visible) is located in compartment 3b. The vessel has a double bottom 6a, 6b and a trap 7 is disposed between the double bottom 6a, 6b and the floor 4 of the compartments 3a and 3b.
Above the floor 4, the bulkhead 2 is essentially imperforate, so as to prevent propagation of fire between the compartments 3a and 3b. The compartments 3a and 3b may be open upward, for example through ventilation ducts equipped with fire closure shutters.
The trap 7 is in the form of a rectangular trough having a horizontal base and longitudinal side walls that extend upward from the base to a rim at the top of the trough. The base of the trough is provided by the bottom 6b and the side walls by longitudinal plate structures 10a and 10b of the vessel. The longitudinal bulkhead 2 extends downward into the trough, where its lower portion 8, below the rim of the trough, divides the trough longitudinally into two portions 9a and 9b. In its lower portion 8, the bulkhead 2 is formed with large flow apertures 11 that provide fluid flow communication between the two portions 9a and 9b. The apertures 11 are positioned below the rim of the trough. The portions 9a and 9b open into the compartments 3a and 3b respectively through apertures 12. Accordingly, fluid is able to flow between the compartments 3a and 3b by way of the apertures 11 and 12 and the portions 9a and 9b of the trough. The lower portion 8 of the bulkhead 2 serves as a baffle that is integrally connected to the imperforate portion of the bulkhead and limits in the upward direction the space available for fluid flow between the portions 9a and 9b.
For safety reasons, the apertures 12 may be covered by gratings 19. The floor 4 may be provided with vertical shields 14 in the vicinity of the apertures 12 to prevent any substance in the trough from spreading or spilling into the compartments. This kind of shield is particularly required if the trap 7 is partially above the level of the floor 4. Alternatively, only the edges of the apertures 12 need to be provided with upwardly projecting collars for the same purpose.
The trap 7 is connected to a substance container 15, for example, a ballast tank or another tank, a pool or the like, from which the trough may be rapidly filled via a tube 16. For safety reasons, it is preferred that the container 15 should always contain enough substance to completely fill up the trough. It is advantageous for the container 15 to be at a clearly higher level than the trap 7 so that the trough is filled by gravity flow from the container. Although not shown in FIG. 1, devices or systems for speeding up the filling process may be provided. Also, a closure valve should be provided in the tube 16. Level indicators, control devices or other devices may also be required. Pressure vessels 17 containing a pressurized substance, such as carbon dioxide, for extinguishing fires, may also be provided, the pressure vessels being connected via tubes 18 to the closed compartment 3a or 3b or to both of them.
The apertures 11 and 12 are arranged so that they fit into the general hull structure of the vessel without weakening it. It is preferred for strength reasons that the lower portion 8 of the bulkhead 2 extend to the bottom of the trough and be firmly attached to the bottom 6b and that the apertures 11 be formed above the lower edge of the bulkhead. Alternatively, or in addition, to forming the apertures 11 in the partition or bulkhead above the lower edge thereof, the bulkhead 2 may terminate above the bottom of the trough defined by the plate structures 10a and 10b and the bottom 6a to provide a gap that allows fluid flow communication between the portions 9a and 9b.
FIG. 1 illustrates a normal situation when there is no immediate need to fill up the trap 7 with water or some other non-gaseous flowable material. However, the arrangement is at full readiness all the time for using the trap 7 in an equilibrating action as well as to prevent the spread of fire.
FIG. 2 shows an accidental damage opening 20 in the outer side of the compartment 3b. Water flowing in through the opening 20 to the compartment 3b flows through the trap 7 and into the compartment 3b. Because the total cross-sectional area of the flow passage defined by the trap 7 is large, the flow of water from the damaged compartment 3b to the compartment 3a takes place rapidly and the stability of the vessel is preserved.
FIG. 3 shows a fire 21 in the compartment 3b. In this case the trap 7 is filled at least approximately to the height of the level of the floor 4 with water from the container 15 through the tube 16. It is important that the water level 22 is above the upper edges of the apertures 11 in order to achieve liquid sealing. Carbon dioxide or some other suitable substance is supplied from the pressure vessels 17 through the tube 18 to the compartment 3b to extinguish the fire.
FIG. 4 shows the apertures 11 which are located in the lower portion 8 of the bulkhead 2 in the vicinity of the bottom 6b of the trap 7. The length of the trap 7 is divided into segments by transverse walls 23 which are spaced apart from 1 to 5 meters, preferably from 2 to 3 meters. The total area of the apertures 11 should be sufficiently great to enable a sufficiently fast water equilibrating action to be achieved. The upper edges of the apertures 11 are at a sufficiently low level for a safe liquid sealing function to be obtained with only a relatively small amount of water.
The filling tube 16 of the trap 7 is installed so that the tube 16 is provided with outflow apertures or tubes 24 in each of the spaces between the transverse walls 23. By providing the transverse walls 23, the water or other substance used to fill the trap 7 cannot flow in the longitudinal direction of the vessel 1. Therefore, the liquid sealing function of the trap arrangement is maintained even if the trim position of the vessel 1 changes.
FIG. 5 illustrates a modified water equilibrating arrangement in which the trough is defined by the floor 4 of the compartments 3a and 3b and two vertical walls that extend upwards from the floor 4. In the arrangement shown in FIG. 5, the bulkhead 2 extends downward into the trough but does not extend as far as the floor 4. A gap for flow of water is formed between the bottom edge of the bulkhead and the base of the trough.
The invention is not to be considered as being limited to the embodiment illustrated since several variations thereof are feasible including variations which have features equivalent to, but not necessarily literally within the meaning of, features in any of the following claims. It will of course be appreciated that the invention is not restricted to use with two compartments that are separated by a single imperforate bulkhead, but is applicable in general to two compartments that are separated across the vessel by a structure that would prevent an equilibrating flow of water between the compartments if it were not for the equilibrating arrangement according to the invention. For example, the invention is applicable to two compartments that have a third compartment therebetween, where the trap extends under the third compartment.
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A water equilibrating arrangement for a marine vessel comprises a trough that is in fluid flow communication with first and second closed or closeable compartments that are separated by an essentially imperforate structure and a baffle that extends downward from the imperforate structure into the trough and defines a passage that provides fluid flow communication between the compartments. In the event that water enters one of the compartments due to damage to the vessel, water can flow rapidly into the other compartment for equilibrating water load in the two compartments. Flow of gas through the trough is prevented when a substantial portion of the trough is filled with a liquid or a flowable solid or semi-solid material.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/490,287 filed Jul. 24, 2003.
FIELD OF INVENTION
This invention relates generally to airbrushes used for spraying colored patterns on fingernails, toenails, skin, or other surfaces. The invention relates more specifically to a compact, portable airbrush with improved mechanisms for aerosolizing the paint and facilitating stenciling.
BACKGROUND
Airbrushes are used to paint thin coats of paint, fingernail polish, ink, dyes, pigments, and other coatings on various surfaces. Substances applied with an airbrush are referred to collectively herein as “paint,” and the act of applying them is referred to herein as “painting.” The act of converting the substance from its original form to what emanates from the air brush is referred to herein as “aerosolizing” the paint. Of particular interest, airbrushes are used to apply paint on fingernails and toenails. Solid-color nails are the easiest to paint. French manicures are more complicated, involving painting the tips of the nails white and the nail beds a more neutral color. Even more popular recently has been painting multiple colors and layers on nails in patterns of various shapes and designs. Some of the designs painted on the nails approach miniature pieces of fine art, with detailed geometric shapes, landscapes, flowers, figures, etc. Because self-application of designs is very difficult, most people go to a salon for their manicures and pedicures, where they can obtain the services of trained and experienced nail technicians.
Some patterns are created by stenciling the nails. That is, a stencil with the desired pattern is applied to the nail, typically with adhesive, and then the paint is sprayed onto the nail. See, for example, U.S. Pat. No. 5,427,121 issued to Polito. The stencil is removed, leaving the pattern on the nail. It is known in the art to use an airbrush that is powered by a commercial-grade compressor to spray the paint. The compressor is large and heavy and is placed on the floor, as opposed to the manicure table. It typically remains in one location, stored at the foot of the nail technician's table whether it is in use or not, because it is not easily portable. It is desirable to have an airbrush that is small and compact so that it could be placed on a table, and that is easily moved and stored elsewhere between uses, particularly for home use.
Another problem with the existing equipment is that it is designed for a nail technician to use on another person's hands. It is nearly impossible to paint one's own nails with known airbrush equipment, because while one hand is being painted, the other is holding the airbrush wand, and an additional hand(s) is needed to hold the stencil in place. It would be desirable to have a mechanism to make painting one's own nails easier.
Further, commercial airbrushes are designed with a wand that has a tiny bowl (hopper) to receive the desired paint. See, for example, U.S. Pat. No. 6,213,131 issued to Viet et al. Nail polish is poured from a bottle of nail polish into the bowl in the desired amount. To change colors, the residual paint in the bowl and wand is forced out with the compressed air and a new color is poured into the bowl. This method of filling the bowl is time consuming, messy, wastes the paint remaining in the wand and can often lead to spilling the paint. Over time, the airbrush gets clogged and must be cleaned with an appropriate solvent or replaced. It is desirable to have an easier way to supply paint to the wand so that paint colors may be easily changed, with no mess or waste.
In addition to painting patterns on nails, air brushes are also used to paint patterns on other surfaces such fabric and clothing; walls; cars; signs; and even painting temporary tattoos on skin. It would be desirable to have a compact airbrush that is portable and that is battery-powered for use at remote locations.
Consequently, it would be desirable to a compact, portable airbrush that has an improved mechanism for aerosolizing the paint and changing the colors. Preferably the device will also have improved mechanism to hold stencils near one's own nails for easier self-application of fingernail polish. It is also desirable that the device be battery-powered for use in remote locations.
SUMMARY OF THE INVENTION
The present invention is a portable airbrush with improved mechanisms for aerosolizing paint and for facilitating stenciling. The device utilizes an air compressor that is compact, portable and relatively lightweight. The air compressor is housed in a base that has projections to hold stencils in positions that make it easier for a person to spray his or her own nails. The stencils are removably attached to the projections with stencil fasteners. The mechanism for aerosolizing the paint arranges an air-emitting nozzle, a paint-emitting needle, and its attached paint reservoir in such a way that when the nozzle and paint reservoir are removed from the wand, substantially no residual paint remains in the wand. The air compressor may be battery-powered or powered by house current, and the device may be packaged in a case with numerous stencils and refillable bottles of paint.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a first embodiment of the device with a first embodiment of the paint assembly and a hand-shaped stencil support. The base is shown in a partial-cutaway view.
FIG. 2 a is a plan view of the first embodiment of the paint assembly in cross-section along line 2 - 2 in FIG. 1 , showing air flow when the aperture is open.
FIG. 2 b is a plan view of the first embodiment of the paint assembly showing air flow when the aperture is closed.
FIG. 3 is a plan view of the paint container and needle.
FIG. 4 is a plan view of a second embodiment of the paint assembly in cross-section.
FIG. 5 illustrates a stencil assembly with a hand-shaped stencil support and finger-shaped projections.
FIG. 6 illustrates a stencil assembly with simple stick projections.
FIG. 7 a illustrates a stencil and stencil ring.
FIG. 7 b illustrates a stencil attached to a stencil ring.
FIG. 8 illustrates practice nail forms.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates the preferred embodiment of the present invention. A source of compressed air 12 is housed in a base 11 . The source is small and relatively lightweight so that the housing can sit on a table, such as a manicure table, and be easily moved and stored elsewhere between uses. Preferably the source weighs less than 10 lbs. The source 12 delivers sufficient air pressure to spray thin, uniform coats of paint with few drips or spots. Preferably the source 12 is an air compressor that is capable of delivering about 0.5-1.0 cfm and maintaining up to about 35 psi. Preferably the source 12 operates at or above 10 psi. Pressure is controlled with a compressor control 9 which, in its simplest form, may be an on/off switch. Air compressors are known in the art. In the preferred embodiment, the device is powered by a battery 8 . However, the device may be powered by house current. Alternatively, the source of compressed air can be provided by canisters of pressurized inert gas, such as that used for CO 2 guns, which are also known in the art.
An air hose 14 is connected to the source 12 to carry compressed air to the wand 15 . The wand 15 comprises a grip 16 , a means for controlling air flow 17 , and a means for attaching the paint to the wand. FIGS. 2 a and 2 b show the preferred means for attaching the paint to the wand with paint assembly 18 . The air flow is controlled by an aperture 7 in the wand 1 between the source of the air and the nozzle 19 . See FIGS. 2 a and 2 b . When the aperture is open, the compressed air is vented through the wand 15 to no effect. When the aperture is closed, air is forced to pass through the nozzle 19 . The means for air flow control may be a simple hole in the wand. Or, as shown in FIG. 1 , it is preferably a biased piston-like knob 17 that reciprocates in the aperture and, when depressed, closes the aperture thereby shunting the air through the nozzle 19 . To close the aperture, the user may simply place his or her finger over the hole or depress the knob 17 .
The paint assembly 18 comprises a nozzle 19 , a container of paint 20 , a means 21 for attaching the paint container 20 to the wand 15 , and a needle 22 through which the paint passes. The container of paint 20 is preferably a bottle having a threaded neck 24 . See FIG. 3 . The needle 22 is either attached to the bottle or integral therewith. The means 21 for attaching the paint container 20 to the wand 15 is preferably an arm 21 a having a matedly-threaded collar 25 at its distal end. The paint container 20 is attached to the wand by screwing the bottle neck 24 to the collar 25 . For additional security, the means 21 for attaching the paint container 20 may further include a resilient clamp 26 that extends from the wand. Ideally the means for attaching the paint container is adjustable so that the paint container may be positioned appropriately under the nozzle to most efficiently aerosolize the paint. Alternative means may be used for attaching the paint container to the wand, such as using the spring clamp alone or a snap-in arrangement.
To aerosolize the paint and achieve the desired fine spray, the aperture is closed with the flow control 17 , forcing air through the nozzle 19 . As the air passes over the tip of the needle 22 , a pressure gradient is created, causing the paint to be drawn out of the paint container 20 . As the paint mixes with the air flow, a fine spray is created. To stop the spray, the aperture is opened by allowing the knob 17 to spring back to its original position. This allows the compressed air to flow through the aperture instead of through the nozzle 19 . To change paints, the paint container 20 is removed from the wand by simply unscrewing the neck from the collar. Since no paint got into the wand, the wand does not need to be cleaned prior to using a different color.
FIG. 4 illustrates a second embodiment of the paint assembly 28 . In this embodiment, the entire paint assembly 28 is removable from the wand 15 . The bottle 20 is attached to the wand 15 directly in front of the nozzle 19 . Preferably the paint assembly 28 snap-fits to the wand 15 . As with the first embodiment, the flow is controlled by an aperture 17 in the wand between the source of the air and the nozzle 19 . When the aperture is open, the compressed air is vented through the wand to no effect. However, in this second embodiment, when the aperture is closed, air is forced to pass by the paint container where it mixes with the paint before it gets to the nozzle. The aerosolized paint is forced through the nozzle to forms a fine spray.
In the second embodiment, the wand 15 has an opening 41 for receiving a paint container 20 which supplies paint to the paint reservoir. The opening is threaded to mate with the neck 24 of the paint bottle 20 . Alternatively, the paint bottle can be firmly positioned in the opening with a snap-fit. The paint may be gravity fed by dripping paint downward from the attached bottle to the wand, or wick-fed in which paint is wicked upward into the wand from a container depending from the wand.
The bottles for any implementation of the present invention may be disposable or refillable.
To make it easier for the user to paint his or her own fingernails, a stencil support 55 is provided. There is at least one projection extending from the stencil support 55 that will serve to hold a stencil 52 for convenient placement on a fingernail. The stencil support 55 has one or more projections 51 a , 51 b , 51 c , 51 d , 51 e which serve to hold one or more stencils 52 . In the preferred embodiment, the stencil support 55 is attached to the base 11 and is configured to look like an up-turned palm, with five projections that are shaped like fingers with long fingernails 60 . See FIG. 1 . The projections' fingernails 60 may be used for practicing the airbrushing. Alternatively, the base may be configured to look like a flower, with the petals serving to hold the stencils the projections can be simple tubular extensions.
While the stencil support is preferably attached to the base, it may also stand alone. See FIG. 5 , for example. The stencil support may also provide an aperture 62 to hold the wand 15 when it is not in use. See FIG. 6 which shows an alternative embodiment of the stencil support with simple upright projections 61 a , 61 b , 61 c , 61 d , and 61 e.
The stencil fastener 53 is a ring 54 that is elastic or has a diameter slightly bigger than the projection. The ring 54 has a means for fastening the stencil 52 to the ring 54 , such as a nib 56 or pinch clip, both illustrated in FIGS. 7 a and 7 b . The stencils are made of firm, but preferably flexible, material such as plastic or paper. Various designs are cut out of the stencil, through which the paint is applied to the nails. The stencil may have a curved shape mimicking the curve of a nail to make French manicures easier.
Quality nail design takes practice. The airbrush user can practice on the projections or on his or her own nails, but constant removal of the paint can be messy. Another disadvantage of painting on ones own nails or the projections is that, if the user paints a particularly appealing design, the design is destroyed when the paint is removed. Therefore, the present invention also includes practice nail forms. See FIG. 8 .
The practice forms 91 are thin, flexible, nail-shaped surfaces that are easily applied and removed to a user's nails or to the projections. Preferably a form is paper or very thin plastic with adhesive 92 on its backside that enables the form to be placed and easily repositioned on the user's nail or on a projection. It is contemplated that a portion of the back of the form be coated with an adhesive that has properties similar to that used on POST-IT® notes sold by 3M. The user then practices painting on the nail form and, when finished, either discards the practice form or saves if for later reference.
While there has been illustrated and described what is at present considered to be a preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made, and equivalents may be substituted for elements thereof without departing from the true scope of the invention. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A portable airbrush with improved mechanisms for aerosolizing paint and for facilitating stenciling. The device utilizes an air compressor that is compact, portable and relatively lightweight. The air compressor is housed in a base that has projections to hold stencils in positions that make it easier for a person to spray his or her own nails. The stencils are removably attached to the projections with stencil fasteners. The mechanism for aerosolizing the paint arranges an air-emitting nozzle, a paint-emitting needle, and its attached paint reservoir in such a way that when the nozzle and paint reservoir are removed from the wand, substantially no residual paint remains in the wand. The air compressor may be battery-powered or powered by house current, and the device may be packaged in a case with numerous stencils and refillable bottles of paint.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority Provisional Application No. 60/672,676, filed Apr. 19, 2005. the disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention generally relates to a method and apparatus for making uniform nanofiber webs, and more specifically relates to a method of making uniform nanofiber webs, wherein a source of process air is utilized to affect the spray pattern and quality of fibrillated material as it is expressed from a die assembly including a multi-fluid opening.
BACKGROUND OF THE INVENTION
[0003] Meltspun technologies, which are known in the art to include the spunbond and meltblown processes, manage the flow of process gases, such as air, and polymeric material simultaneously through a die body to effect the formation of the polymeric material into continuous or discontinuous fiber. In most known configurations of meltblowing nozzles, hot air is provided through a passageway formed on each side of a die tip. The hot air heats the die and thus prevents the die from freezing as the molten polymer exits and cools. In this way the die is prevented from becoming clogged with solidifying polymer. In addition to heating the die body, the hot air, which is sometimes referred to as primary air, acts to draw, or attenuate the melt into elongated micro-sized filaments. In some cases, a secondary air source is further employed that impinges upon the drawn filaments so as to fragment and cool the filaments prior to being deposited on a collection surface. Typical meltblown fibers are known to consist of fiber diameters less than 10 microns.
[0004] More recently, methods of forming fibers with fiber diameters less than 1.0 micron, or 1000 nanometers, have been developed. These fibers are often referred to as ultra-fine fibers, sub-micron fibers, or nanofibers. Methods of producing nanofibers are known in the art and often make use of a plurality of multi-fluid nozzles, whereby an air source is supplied to an inner fluid passageway and a molten polymeric material is supplied to an outer annular passageway concentrically positioned about the inner passageway. While the physical properties of nanofiber webs are advantageous to a variety of nonwoven markets, commercial products have only reached limited markets due to associated cost.
[0005] U.S. Pat. No. 5,260,003 and No. 5,114,631 to Nyssen, et al., both hereby incorporated by reference, describe a meltblowing process and device for manufacturing ultra-fine fibers and ultra-fine fiber mats from thermoplastic polymers with mean fiber diameters of 0.2-15 microns. Laval nozzles are utilized to accelerate the process gas to supersonic speed; however, the process as disclosed has been realized to be prohibitively expensive both in operating and equipment costs.
[0006] U.S. Pat. No. 6,382,526 and No. 6,520,425 to Reneker, et al., also both hereby incorporated by reference, disclose a method of making nanofiber by forcing fiber forming material concentrically around an inner annular passageway of pressurized gas. The gas impinges upon the fiber forming material in a gas jet space to shear the material into ultra-fine fibers. U.S. Pat. No. 4,536,361 to Torobin, incorporated herein by reference, teaches a similar nanofiber formation method wherein a coaxial blowing nozzle has an inner passageway to convey a blowing gas at a positive pressure to the inner surface of a liquid film material, and an outer passageway to convey the film material. An additional method for the formation of nanofibers is taught in U.S. Pat. No. 6,183,670 to Torobin, et al., which is hereby incorporated by reference.
[0007] Spacing of nozzles within the die body may be arranged such that material exiting the nozzle arrangement can be collected in a more uniform manner upon a forming surface. It has been recognized that a linear formation of equally spaced nozzles may result in a striping pattern that is visibly noticeable within the collected web. The stripes are found to reflect the spacing between adjacent nozzles. The striping effect seen in the web can further be described as “hills and valleys” whereby the “hills” exhibit a noticeably higher basis weight than that of the “valleys”. The industry may also refer to such basis weight inconsistencies as gauge bands.
[0008] U.S. Pat. No. 5,582,907 and No. 6,074,869, both incorporated herein by reference, address striping observed in meltblown webs by organizing nozzles into two linearly arranged parallel rows each having substantially equally spaced. Additionally, the two rows of nozzles are offset such that the nozzles are staggered in relationship to each other. Further, the staggered nozzles of the two rows are angled inward toward each other. In this fashion, each nozzle is utilizing a respective supply of primary process air, but lacks an ancillary air source to assist with web formation. These patents further assert external disruption of the polymeric material by an alternate gas source detracts from achievement of sufficient web uniformity.
[0009] A need remains for a process that can utilize multi-fluid openings for facilitating the distribution of molten polymer and a gas in the formation of nanofibers and further incorporates an ancillary gas source that assists with a uniform fiber collection across the width of the web.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a method and apparatus for making nanofiber webs, wherein a source of process air is utilized to affect the spray pattern and quality of fibrillated material expressed from a die assembly including a multi-fluid opening. Appropriately, the aforementioned process air is defined herein as an alternate or ancillary air source apart from primary process air, which primary air is simultaneously supplied with the molten polymeric material to the fiber forming multi-fluid opening. The ancillary air source of the invention is further distinct from secondary air, which is also known in the art as quenching air. The ancillary air can be described as a continuous fluid curtain of shielding or shaping air. While the use of air is preferred, the invention contemplates the use of alternate suitable gases, such as nitrogen. For the purpose of this disclosure, the ancillary air is referred to herein as a “fluid curtain nozzle” or “continuous air curtain”.
[0011] According to the present invention, disclosed herein is a method of forming uniform nanofiber webs, The method includes a multi-fluid opening, wherein the opening includes a passage for directing a gas and a separate passage for directing a polymeric material through the opening. The method further includes at least one fluid curtain nozzle positioned in operative association with the multi-fluid opening. According to the method of the present invention, a molten polymeric material and a gas fluid is simultaneously supplied to separate respective passages of the multi-fluid opening. The gas is directed through the multi-fluid opening to impinge upon the polymeric material to thereby form a spray pattern. A fluid is also directed through the fluid curtain nozzle for controlling the spray pattern of nanofiber expressed from the multi-fluid opening and subsequently, the nanofiber is collected on a surface to form a uniform nanofiber web.
[0012] In addition to controlling the spray pattern of the nanofiber expressed from the multi-fluid opening, the fluid curtain is believed to further control the temperature of the multi-fluid opening, wherein the temperature of the multi-fluid opening may be elevated by fluid curtain.
[0013] In one embodiment, continuous air curtains are employed to affect the spray pattern and quality of fibrillated material as the material is expressed from a multi-fluid opening including an array of two or more multi-fluid nozzles. The multi-fluid nozzles have an inner passageway for directing a first fluid, such as gas, and an outer annular passageway surrounding the inner passageway for directing a second fluid or molten polymeric fiber forming material. In addition, at least one continuous air curtain is positioned in operative association with the complete plural nozzle array to affect the polymeric spray formation pattern, which can be generally described as conical. The one or more air curtains are observed to “compress” and shape the spray pattern of fibrillated material that is emitted from the nozzles thereby decreasing the distance from which the fibers are spaced across the conic spray formation. Further, as the air curtains impinge upon the polymeric spray to affect the spray pattern, the air curtains can also function to shield the spray formations between adjacent plural nozzle arrays to diminish interaction or comingling of the fibrous material between adjacent nozzle arrays. Reduced comingling of the fibrillated polymeric spray of nanofiber between adjacent nozzle arrays is believed to significantly improve the uniformity of the web as the nanofibers are gathered onto a collection surface.
[0014] In one contemplated embodiment, a method for forming the uniform nanofiber web comprises an array of two or more multi-fluid nozzles preferably aligned in a generally linear arrangement, wherein a plurality of the multi-fluid nozzle arrays are positioned parallel to one another across the width of the fiber forming apparatus. In addition, at least one air curtain nozzle is positioned in operative association with each of the plural multi-fluid nozzle arrays, wherein the air curtain nozzle defines a generally elongated slot through which fluid is directed for formation of the fluid (air) curtain.
[0015] The present invention also contemplates the use of one or more air curtains with various other multi-fluid opening configurations, such as slot dies. Examples of slot die configurations include a double slot die and a single slot die. It is believed that the use of one or more air curtains in operative association with the double slot multi-fluid opening or single slot multi-fluid opening affects fiber formation and enhances the uniformity of the resultant web.
[0016] Other features and advantages of the present invention will become readily apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic diagram of the effect of the air curtains on the polymeric spray formations of the multi-fluid nozzle configurations;
[0018] FIG. 2 is a schematic diagram of an array of annular nozzles embodying the principle of the present invention;
[0019] FIG. 3 is a schematic diagram of a slot die assembly embodiment of the present invention;
[0020] FIG. 4 is a schematic diagram of an alternate slot die assembly embodiment of the present invention; and
[0021] FIG. 5 is a schematic diagram of still another alternate non-annular embodiment of the present invention.
DETAILED DESCRIPTION
[0022] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings, and will hereinafter be described, a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.
[0023] The method of making nanofiber webs in accordance with the present invention can be practiced in keeping with the teachings of U.S. Pat. No. 4,536,361 and No. 6,183,670, both previously incorporated herein by reference. The present invention further contemplates a method of forming fibrillated nanofibers and nanofiber webs, wherein one embodiment, shown in FIG. 2 , includes a die assembly 20 including an array of plural multi-fluid nozzles 28 . Each nozzle defines an inner fluid passageway for directing a gas 24 , and an outer passageway, wherein the outer passageway surrounds the inner passageway for directing polymeric material 22 through the nozzle. In addition, at least one fluid curtain nozzle 26 , or “air curtain” nozzle, is positioned in operative association with each array of plural multi-fluid nozzles. While the use of air through the fluid curtain nozzle may be preferred, the invention contemplates the use of alternate suitable gases, such as nitrogen.
[0024] FIG. 1 is a schematic view illustrating the influence of the air curtains in relation to individual nozzles. The air curtains shape and shield the spray pattern of the nozzles to reduce comingling between adjacent fibrous spray patterns of fibrillated material. FIG. 2 is a schematic view of the multi-fluid nozzle arrays 28 , wherein at least one air curtain 26 is positioned within operative association with the array 28 . As demonstrated in FIG. 1 , the air curtains shape the spray pattern of fibrillated material emitted from the nozzles within the array and further shields the spray formations of adjacent multi-fluid nozzle arrays.
[0025] It is also in the purview of the present invention to provide a die assembly including a slot configuration for delivery of a gas and a polymeric material. In such a configuration, it is contemplated to provide a polymeric material as a continuous film on a film forming surface, wherein non-limiting examples of film forming surfaces may include linear, wave-like, grooved, and the like. FIG. 3 is an illustrative embodiment a slot configuration, wherein the film forming surface 32 is linear. The slot configuration shown in FIG. 3 , is also referred to as a double slot-die assembly 30 , A double slot-die assembly defines a pair of linear film forming surfaces 32 arranged in converging relationship to each other. In accordance with the invention, the double slot-die assembly defines an elongated gas passage 34 for directing pressurized gas against molten polymer on both pair of linear film forming surfaces 32 . Film fibrillation is believed to occur once the path(s) of the film and gas intersect which may begin to occur as the film descends against the film forming surfaces and may continue to occur as the film is deposited into the gaseous stream. In addition, at least one fluid curtain nozzle 36 , or “air curtain” nozzle, is positioned in operative association with each film forming surface. Again, while the use of air through the fluid curtain nozzle may be preferred, the invention contemplates the use of alternate suitable gases, such as nitrogen.
[0026] In another illustrative embodiment, as shown in FIG. 4 , another die assembly 40 including a slot configuration, wherein a pair of linear film forming surfaces 42 are defined and arranged in parallel relationship to each other. Further, a pair of gas passages 44 arranged in converging relationship for each directing pressurized gas for impingement against respective film forming surfaces 42 . In addition, this embodiment, further includes at least one fluid curtain nozzle 46 , or “air curtain” nozzle, is positioned in operative association with each film forming surface.
[0027] In yet another illustrative embodiment, as shown in FIG. 5 , the slot configuration is also referred to as a single slot-die assembly 50 , which defines at least one gas exit passage 54 and one film forming surface 52 . Pressurized gas from a gas plenum chamber (not shown) is directed through a gas exit passage 54 , which in this illustrated embodiment is disposed at an acute angle to the film forming surface 52 . In addition, at least one fluid curtain nozzle 56 , or “air curtain” nozzle, is positioned in operative association with the film forming surface.
[0028] In yet another embodiment, the slot configuration includes a film forming surface, a gas exit passage, and an impingement surface, wherein the gas exiting the die is directed against the formed film on an impingement surface. In such an embodiment, the film forming surface may be a horizontal surface, otherwise referred to as 0°, or positioned at an angle up to about 80°. Preferably, the film forming surface is positioned at about 0° to about 60°. The film forming surface can be described to also have a length. The film forming surface preferably has a length of about 0 to about 0.120 inches. In addition, the impingement surface also has a preferred surface position, wherein the impingement surface may be perpendicular to the film forming surface or otherwise described as having a 90° angle relative to the film forming surface or the impingement surface may be at an angle than 90° relative to the film forming surface. Further, the impingement surface has a preferred length of between about 0-0.150 inches, more preferably between about 0-0.060 inches, and most preferably between about 0-0.001 inches.
[0029] According to the invention molten polymeric material suitable for formation of the nanofibers and nanofiber webs of the present invention are those polymers capable of being meltspun including, but are not limited to polyolefin, polyamide, polyester, poly(vinylchloride), polymethylmethacrylate (and other acrylic resins), polystyrene, polyurethane, and copolymers thereof (including ABA type block copolymers), polyvinylalcohol in various degrees of hydrolysis in cross-linked and non-cross-linked forms, as well as elastomeric polymers, plus the derivatives and mixtures thereof. Modacrylics, polyacrylonitriles, aramids, melamines, and other flame-retardant polymers have been contemplated as well. The polymers may be further selected from homopolymers; copolymers, and conjugates and may include those polymers having incorporated melt additives or surface-active agents.
[0030] As illustrated in FIG. 1 , the polymeric material is supplied to the outer passageways of the nozzle, a fluid, typically air, is simultaneously supplied through the respective inner passageway of each nozzle to impinge upon the polymeric material directed through the respective outer passageway to thereby form a spray pattern of fibrillated nanofibers from each nozzle. The spray pattern formed from the array of plural multi-fluid nozzles is affected by at least one air curtain nozzle, wherein said air curtain nozzle defines a generally elongated slot, as illustrated in FIG. 2 .
[0031] In such an embodiment, the slot may demonstrate a linear configuration, which is positioned in operative association with the entire array of nozzles to control and shape the spray patterns of the array. Preferably, the slot has a length of about at least the length of the plural multi-fluid nozzle array, and most preferably has a length which is approximately equal to the length of the array plus two times the center-to-center spacing of the individual nozzles. Thus, in a current embodiment, wherein a nozzle array includes three individual nozzles spaced approximately 0.42 in, center-to-center an associated air curtain nozzle has a slot length of approx. 1.7 in. Further, the slot preferably is provided with a width of about 0.003 in. to about 0.050 in. Air temperatures suitable for use with the process of the present invention preferably exhibit a range between 10° C. and 400° C., and more preferably exhibit a range between 25° C. and 360° C.
[0032] The air curtain has been observed to further shield the spray patterns of adjacent multi-fluid nozzle arrays, thereby reducing the degree of comingling between the multi-fluid nozzle arrays, as well as minimizing excess comingling of fibers of adjacent multi-fluid nozzles within an array. In addition, with respect to the slot configuration embodiments, the air curtain is further believed to affect the shape of the spray pattern of the fibrillated film. Without intending to be bound by theory, it is believed that a controlled spray pattern of fibrillated material results in a more uniform collection of nanofibers on a surface to produce a more uniform web.
[0033] Web uniformity usually refers to the degree of consistency across the width of the web and can be determined by several systems of measurement, including, but not limited to, coefficient of variation of pore diameter, air permeability, and opacity. Web uniformity metrics tend to be basis weight dependent. The nonwoven nanofiber fabric of the present invention may exhibit basis weights ranging from very light to very heavy, wherein the range captures fabric less than 5 gsm through fabrics greater than 200 gsm.
[0034] One acceptable uniformity metric is disclosed in U.S. Pat. No. 5,173,356, which is hereby incorporated by reference and includes collecting small swatches taken from various locations across the width of the web (sufficiently far enough away from the edges to avoid edge effects) to determine a basis weight uniformity. Additional acceptable methods for evaluating uniformity may be practiced in accordance with original paper, “Nonwoven Uniformity—Measurements Using Image Analysis”, disclosed in the Spring 2003 International Nonwovens Journal Vol. 12, No. 1, also incorporated by reference.
[0035] Despite the aforementioned methods of evaluating uniformity, lighter weight webs may nonetheless exhibit non-uniform performance characteristics due to differences in the intrinsic properties of the individual web fibers. As taught in U.S. Pat. No. 6,846,450, incorporated herein by reference, light weight webs may be evaluated for uniformity by measuring properties of the fibers rather than the web. It's been further contemplated to measure web uniformity in an inline process by way of various commercially available scanning devices that monitor web inconsistencies. In addition to improved web uniformity, it's believed the nanofiber web formed on the collection surface exhibits a loftier caliper as the nanofibers are deposited in a more controlled manner through the use of air curtains.
[0036] The present invention further contemplates the use of air curtains to improve the quality of the fibrillated material by forming more uniform nanofibers and creating a controlled environment from the time the polymer is first sprayed from the die assembly until the time the formed nanofibers are gathered on a collection surface. Fiber uniformity may be measured by those methods known in the art, such as by a scanning electron microscopic once the fabric is offline or inline by way of ensemble laser diffraction, as disclosed in original paper, “Ensemble Laser Diffraction for Online Measurement of Fiber Diameter Distribution During the Melt Blown Process, of the Summer 2004 International Nonwovens Journal, which is hereby incorporated by reference. Without intending to be bound by theory, when air curtains are used in conjunction with an array or two or more multi-fluid nozzles, it is believed that the air curtains form a controlled gradient-like effect of ancillary air as it diverges from the multi-fluid nozzle tip toward the fiber collection surface. In the region of the nozzle tip, the air currents influence the fiber formation process by acting to control the temperature at the nozzle tip. This control can include elevating the temperature of the fluid nozzles with the fluid (air) current. As the air from the curtains diverges from the nozzle tip, the air curtains of the invention are believed to entrain surrounding environmental air, which acts to isolate the newly formed nanofibers, while minimizing the deleterious effects of “shot” on web formation. Shot is known in the art as a collection of polymer that fails to form fiber during the fiber formation process and deposits onto the fiber collection surface as a polymeric globule deleteriously affecting the web formation.
[0037] In accordance with the present invention, the formed nanofibers are generally self bonding when deposited on a collection surface; however, it is in the purview of the present invention that the nanofiber web may be further consolidated by thermal calendaring or other bonding techniques known to those skilled in the art. It is further in the purview of the invention to combine the nonwoven nanofiber web of the present invention with additional fibrous and non-fibrous substrates to form a multilayer construct. Substrates which can be combined with the nanofiber web (N) may be selected from the group consisting of carded webs (C), spunbond webs (S), meltblown webs (M), and films (F) of similar or dissimilar basis weights, fiber composition, fiber diameters, and physical properties. Non-limiting examples of such constructs include S-N, S-N-S, S-M-N-M-S, S-N-N-S, S-N-S/S-N-S, S-M-S/S-N-S, C-N-C, F-N-F, etc., wherein the multilayer constructs may be bonded or consolidated by way of hydraulic needling, through air bonding, adhesive bonding, ultrasonic bonding, thermal point bonding, smooth calendaring, or by any other bonding technique known in the art.
[0038] The nonwoven construct comprised of the uniform nanofiber web may be utilized in the manufacture of numerous home cleaning, personal hygiene, medical, and other end use products where a nonwoven fabric can be employed. Disposable nonwoven undergarments and disposable absorbent hygiene articles, such as a sanitary napkins, incontinence pads, diapers, and the like, wherein the term “diaper” refers to an absorbent article generally worn by infants and incontinent persons that is worn about the lower torso of the wearer can benefit from the improved uniformity of a nanofiber nonwoven in the absorbent layer construction.
[0039] In addition, the material may be utilized as medical gauze, or similar absorbent surgical materials, for absorbing wound exudates and assisting in the removal of seepage from surgical sites. Other end uses include wet or dry hygienic, anti-microbial, or hard surface wipes for medical, industrial, automotive, home care, food service, and graphic arts markets, which can be readily hand-held for cleaning and the like.
[0040] The nanofiber webs of the present invention may be included in constructs suitable for medical and industrial protective apparel, such as gowns, drapes, shirts, bottom weights, lab coats, face masks, and the like, and protective covers, including covers for vehicles such as cars, trucks, boats, airplanes, motorcycles, bicycles, golf carts, as well as covers for equipment often left outdoors like grills, yard and garden equipment, such as mowers and roto-tillers, lawn furniture, floor coverings, table cloths, and picnic area covers.
[0041] The nanofiber material may also be used in top of bed applications, including mattress protectors, comforters, quilts, duvet covers, and bedspreads. Additionally, acoustical applications, such as interior and exterior automotive components, carpet backing, insulative and sound dampening appliance and machinery wraps, and wall coverings may also benefit from the nanofiber web of the present invention. The uniform nanofiber web is further advantageous for various filtration applications, including bag house, plus pool and spa filters.
[0042] It has also been contemplated that a multilayer structure comprised of the nanofiber web of the present invention may be embossed or imparted with one or more raised portions by advancing the structure onto a forming surface comprised of a series of void spaces. Suitable forming surfaces include wire screens, three-dimensional belts, metal drums, and laser ablated shells, such as a three-dimensional image transfer device. Three-dimensional image transfer devices are disclosed in U.S. Pat. No. 5,098,764, which is hereby incorporated by reference; with the use of such image transfer devices being desirable for providing a fabric with enhanced physical properties as well as an aesthetically pleasing appearance.
[0043] Depending on the desired end use application of the uniform nonwoven nanofiber web, specific additives may be included directly into the polymeric melt or applied after formation of the web. Suitable non-limiting examples of such additives include absorbency enhancing or deterring additives, UV stabilizers, fire retardants, dyes and pigments, fragrances, skin protectant, surfactants, aqueous or non-aqueous functional industrial solvents such as, plant oils, animal oils, terpenoids, silicon oils, mineral oils, white mineral oils, paraffinic solvents, polybutylenes, polyisobutylenes, polyalphaolefins, and mixtures thereof, toluenes, sequestering agents, corrosion inhibitors, abrasives, petroleum distillates, degreasers and the combinations thereof. Additional additives include antimicrobial composition, including, but not limited to iodines, alcohols, such as such as ethanol or propanol, biocides, abrasives, metallic materials, such as metal oxide, metal salt, metal complex, metal alloy or mixtures thereof, bacteriostatic complexes, bactericidal complexes, and the combinations thereof.
[0044] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.
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The present invention is directed to a method and apparatus for making nanofiber webs, wherein a source of process air is utilized to affect the spray pattern and quality of fibrillated material expressed from a die assembly including a multi-fluid opening. Appropriately, the aforementioned process air is defined herein as an alternate or ancillary air source apart from primary process air, which primary air is simultaneously supplied with the molten polymeric material to the fiber forming multi-fluid opening. The ancillary air source of the invention is further distinct from secondary air, which is also known in the art as quenching air. The ancillary air can be described as a continuous fluid curtain of shielding or shaping air.
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TECHNICAL FIELD
The present invention relates generally to a safety system for operators of industrial vehicles, and more particularly to a seatbelt-activated system adapted for locking out predetermined controls of a skid-steer loader responsive to fastening of the seatbelt by the operator.
BACKGROUND ART
There are various types of industrial vehicles in use today, and one of the most popular of these is the skid-steer loader. A skid-steer loader is a compact, highly maneuverable vehicle in which the wheels on opposite sides of the vehicle are independently driven through hydrostatic transmissions. Maneuvering is accomplished by driving the wheels on each side of the vehicle at different speeds and/or in different directions. The operator sits in front of the engine and between the arms of a hydraulically operated boom on which a bucket, grapple fork, rake, auger or other accessory can be mounted. A cab or roll cage is usually provided about the operator's compartment for protection.
Seatbelts traditionally have been provided for restraining the operator in the vehicle during operation. Seatbelts, of course, depend upon the operator to fasten them so that they can serve their intended purpose. Accidents and injuries have occurred when operators were not wearing their seatbelts and were pitched forward. Moreover, heretofore the functions of seatbelts and control interlocks have not been interrelated.
Other than encouraging operators to wear their seatbelts, attempts have been made to develop auxiliary restraint systems and/or control interlock systems for improving safety. Such control interlock systems are especially desireable in skid-steer loaders where the operators must climb into and out of their seats from the front of the vehicles and directly over the controls. For example, the Bobcat loader available from the Melroe Division of Clark Equipment Company utilizes a pivotal seat bar. When the bar is in the up position, the foot pedals and the boom lift arms are locked and the operator can easily enter or exit the vehicle. When the seat bar is down, the controls are unlocked and the bar provides additional protection against the operator pitching forward during operation of the vehicle. This type of restraint system, however, is completely independent of the seatbelt, and does not function in any way to encourage the operator to fasten his seatbelt as well. Moreover, this type of swing down seat bar is somewhat unwieldy and expensive.
Seat-activated devices also have been utilized heretofore, however, these have certain disadvantages. For example, the skid-steer loaders from Sperry New Holland incorporate seat-activated systems which deactivate the boom hydraulics if the operator comes off the seat for any reason. Such systems are extremely sensitive to bouncing of the operator in the seat. Operation by a lightweight operator and/or over rough terrain can cause multiple cycling leading to increased wear and maintenance. Again, operation of this type system is completely independent of the seatbelt.
There is thus a need for an improved operator restraint/control lockout system of unobtrusive construction which functions to positively lockout predetermined controls of the vehicle unless the seatbelt is properly fastened.
SUMMARY OF INVENTION
The present invention comprises a seatbelt-activated system which overcomes the foregoing and other difficulties associated with the prior art. In accordance with the invention, there is provided a seatbelt activated operator restraint/control lockout system which is particularly adapted for use with a skid-steer loader and which provides positive lockout of predetermined controls, such as the lift arm control valves, when the seatbelt is not properly fastened. The system includes a pivot arm adapted for connection at one end to one side of the seatbelt. The other end of the pivot arm is connected by a linkage to a catch plate moveable between locked and unlocked positions with respect to the control valve. The pivot arm is normally urged by a spring to a rearward position wherein the catch plate locks the spool(s) of the control valve against movement by the pedals. Properly fastening the seatbelt causes the pivot arm to move to a forward position wherein the catch plate is lifted out of interfering engagement with the control valve, freeing it for operation by manual controls.
BRIEF DESCRIPTION OF DRAWINGS
A better understanding of the invention can be had by reference to the following Detailed Description in conjunction with the accompanying Drawings, wherein;
FIG. 1 is a side view of a skid-steer vehicle for which the safety system of the invention is particularly adapted;
FIG. 2 is an enlarged side view of the operator's seat relative to a portion of the system herein;
FIG. 3 is an exploded perspective view of the seatbelt connections;
FIG. 4 is a side view of the invention;
FIG. 5 is a top view of the invention;
FIG. 6 is an end view of the foot pedal control linkages; and
FIG. 7 is a diagram of an alternate embodiment of the invention.
DETAILED DESCRIPTION
Referring now to the Drawings, wherein like reference numerals designate like or corresponding elements throughout the views, and particularly referring to FIG. 1 there shown a skid steer vehicle 10 for which the operator restraint/control lockout system of the invention is particularly adapted. The skid-steer vehicle 10 includes a frame 12 with a set of wheels 14 mounted on each side thereof on a relatively short wheel base. A rear mounted engine 16 independently drives the wheels 14 on each side by means of hydrostatic transmissions (not shown).
An operators compartment 18 is defined by a roll cage 20 and seat 22 located between a pair of lift arms 24. The inner ends of the lift arms 24 are pivoted at points 26 to upright portions of the frame 12 behind the operators compartment 18. An implement such as a bucket 28 is pivoted to the outer ends of the lift arms 24 at points 30. Raising and lowering of the lift arms 24 is accomplished by means of double-acting cylinders 32, while cylinders 34 are provided for tilting the bucket 28. Suitable controls including foot pedals and a T-bar handle or hand levers (not shown) are provided inside the operators compartment 18 for controlling the skid steer vehicle 10. Also provided is a seatbelt 36 which functions in conjunction with the seatbelt activated operator restraint/control lockout system 40 of the invention, as will be explained more fully hereinafter, to provide a positive mechanical lockout of the valve controlling the cylinders 32 and 34 when the seatbelt is not properly fastened.
FIGS. 2 and 3 illustrate the connection between the seatbelt 36 and the operator restraint/control lockout system 40. The seatbelt 36 includes two sides or portions 36a and 36b. The seatbelt portion 36a is of fixed length and includes a tongue 42 adapted for receipt by buckle 44 of the other seatbelt portion 36b, which is of adjustable length. The other ends of the seatbelt portions 36a and 36b are secured to frame 12. In particular, portion 36a is secured to a pivot arm 46 and a flat spring 48 by means of a fastener 50. The upper end of the flat spring 48 is adapted to fit into a pocket 52 formed at the lower end of the seatbelt portion 36a. The purpose of spring 48 is to present part of the seatbelt 36 for the convenience of the operator. The lower end of the seatbelt portion 36a, the pivot arm 46 and the flat spring 48 are thus rigidly interconnected by the fastener 50. The arm 46 and spring 48 in turn are pivoted by a common pin 54 to a support bracket 56 mounted on a seat plate 58. The pivot arm 46 extends through a slot 60 in plate 56 and connects to the remainder of system 40. The lower end of the other seatbelt portion 36b is secured by a fastener 62 to a bracket 64 which is anchored to plate 58 by another fastener 66.
It will thus be understood that one end of the seatbelt 36 is secured to a fixed bracket 64, while the other end is attached to a pivot arm 46. Brackets 56 and 64 are laterally spaced apart and preferably located well back with respect to the operator seat 22 so that pivotal positioning of the pivot arm 46 will vary in accordance with whether the seatbelt 36 is properly fastened. The position of the pivot arm 46 in turn controls the locked or unlocked condition of the remainder of system 40 as will be explained below.
Referring now to FIGS. 4 and 5 in conjunction with FIG. 2, the lower end of the pivot arm 46 is pivoted at point 68 to one end of a rigid link 70. The link 70 extends through an opening in a bracket 72, and a compression spring 74 is provided between the bracket and a follower 76 on the bent link for purposes of normally biasing the pivot arm 46 backward relative to seat 22.
The other end of link 70 is pivoted at point 77 to a catch plate 78, which in turn is connected to a mounting bracket 80 by means of a pin 82. The bracket 80 is mounted on a floor plate 84 of the frame 12. It will thus be apparent that there is a direct mechanical connection between arm 46 and catch plate 78, and that the spring 74 normally biases the arm backwards and the plate downwards.
Referring now to FIG. 6 in conjunction with FIGS. 4 and 5, the catch plate 78 is located adjacent to a control valve 86. As illustrated, valve 86 controls operation of the lift arms 24 and the bucket 28 or any other accessory mounted thereon. In particular, the control valve 86 includes three spools 88, 90 and 92 which are independently moveable by the operator to control flow of hydraulic fluid to the cylinders 32 and 34, and thereby control operation of the lift arms and/or any implement mounted thereon. Such control is typically accomplished by means of foot pedals 94, 96 and 98 while speed and directional control of the vehicle is maintained via a T-bar handle or other hand controls (not shown).
The pedals 94, 96 and 98 are pivoted about a common shaft 100 extending between spaced apart sidewalls of the frame 12. Pedals 94, 96 and 98 are respectively coupled to their valve spools 88, 90, 92 by linkages 102, 104 and 106. Each of the linkages 102, 104 and 106 is preferably connected to its corresponding valve spool by means of a stirrup and cross member to provide the requisite clearance with the catch plate 78. For example, as is best seen in FIG. 4, a stirrup 108 and cross member 110 are provided at the interconnection between linkage 102 and valve spool 88, which typically controls the tilt cylinders 34. Similar stirrups and cross members are provided at the point of the interconnection between linkage 104 and valve spool 90, which typically controls the lift cylinder 32, and at the point of interconnection of the linkage 106 and valve spool 92, which typically controls actuation of an auxiliary device, such as an auger, grapple or the like mounted on the ends of the lift arms 24. The cross members on valve spools 88 and 90 are received in notches formed in the catch plate 78 to facilitate mechanical lockout of valve 86 with its valve spools in their neutral positions.
As illustrated, only the valve spools 88 and 90 for the lift and tilt cylinders of the lift arms 24 are affected by the catch plate 78 because it is sometimes desirable to leave the other valve spool 92 free so that the auxiliary device can be operated while the operator is outside the vehicle 10, however, only one of the valve spools or all three of the valve spools can be locked-out in this manner, if desired.
The seatbelt-activated operator restraint/control lockout system 40 of the invention operates as follows. When the seatbelt 36 is unfastened, either with or without the operator seated in seat 22, the spring 74 urges link 70 away from bracket 72 such that the catch plate 78 is normally urged toward a down and locked position as shown in FIG. 4, while the pivot arm 46 is simultaneously urged backwardly toward the position shown in phantom lines in FIG. 2. When seatbelt 36 is unfastened, the normal condition of system 40 is thus for the valve spools 88 and 90 of control valve 86 to be mechanically locked in their neutral positions such that the cylinders 32 and 34 can not inadvertently be actuated by pedal 94 and 98, as might otherwise happen as the operator is entering or exiting compartment 18. This condition is maintained until the operator is seated in seat 22 with the seatbelt 36 properly fastened. In properly fastening seatbelt 36, the operator must pull the portion 36a forwardly and thus move the pivot arm 46 and link 70 against spring 74 so that the catch plate 78 is lifted out of locking engagement with the control valve 86. The spring 74 returns the catch plate 78 to its normal down and locked position upon release of the seatbelt 36.
Referring now to FIG. 7, there is shown an operator restraint/control lockout system 112 incorporating a second embodiment of the invention. The system 112 includes some components which are substantially identical in construction and operation to components of the system 40 illustrated in FIGS. 2-6. Such identical components are designated in FIG. 7 with the same reference numerals utilized in the description of system 40, but are differentiated therefrom by means of a prime (') notation.
The primary distinction between the two embodiments comprises the fact that system 112 is adapted for use with a system having an electrically or hydraulically actuated control valve instead of a mechanically actuated control valve. In particular, link 70' has been adapted to function as a plunger for engaging the contactor of a switch 114, which can be an electric switch, solenoid valve, or a hydraulic valve. The on or off signals from switch 114 are transmitted through lines 116 to the lift cylinders 32 and preferably also to the tilt cylinders 34. Spring 74 normally urges the pivot arm 46' such that the plunger or the link 70' is out of contact with the switch 114 which is thus deactivated. Otherwise, the system 112 is similar in function and operation to system 40 described above.
From the foregoing, it will thus be apparent that the present invention comprises an operator restraint/control lockout system having numerous advantageous over the prior art. Instead of using an auxiliary device which functions separately and independently of the seatbelt, the system herein is seatbelt-activated such that certain predeterminded controls are postively locked out against operation unless the seatbelt is properly fastened by the operator. The system herein is not sensitive to weight variations of the operator or bouncing of the operator in the seat. Other advantages will be evident to those skilled in the art.
Although particular embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the specific embodiments disclosed, but is intended to embrace any alternatives, equivalents, modifications and/or rearrangements of elements following within the scope of the invention as defined by the claims.
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The specification discloses a seatbelt-activated operator restraint/control lockout system (40) which is particularly adapted for use with industrial vehicles such as skid-steer loaders. A pivotal arm (46) connected to one side of the seatbelt (36) is moveable between a forward position corresponding to the seatbelt being fastened, and a rearward position corresponding to the seatbelt being unfastened. The pivot arm (46) is normally biased by a spring (74) to the rearward position, and means (70, 78) are provided for selectively locking out a control valve (86) against operation except when the pivot arm is in the forward position. A second embodiment (112) of the invention is particularly adapted for use with solenoid-activated control valves.
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FIELD OF THE INVENTION
This invention is directed generally to clothes dryers, and more particularly, to safety systems for clothes dryers.
BACKGROUND
Conventional clothes dryers are constructed of a tumbler configured to hold clothes, a motor for rotating the tumbler, a heating element for heating air, a fan for blowing the heated air across the clothes while the clothes are in the tumbler, and an exhaust conduit for venting the heated air from the dryer. The heating element may be electric or gas powered. Because a close dryer includes a heating element, there always exists the chance of fire. Conventional clothes dryers include many different safety devices for reducing the likelihood of a fire. For instance, a conventional clothes dryer often includes a lint screen for removing lint from the air coming from a tumbler. The lint screen is often placed in an easily accessible location, such as in a slot in a top surface of the clothes dryer, and covers an exhaust conduit where the conduit leaves the tumbler. The lint screen collects lint from the air that has been picked up from the clothing in the tumbler. Most, if not all, manufacturers of clothes dryers recommend that lint screens be cleaned after each load of clothes is dried. Otherwise, an unacceptable amount of lint may build up on the lint screen and pose a fire hazard and prevent efficient operation.
Clothes dryers also typically contain heat sensors, such as thermocouples, for preventing dryers from overheating and causing fires. Most clothes dryers position a thermocouple proximate to a heating element of the clothes dryer. In this position, the thermocouple is capable of monitoring the area surrounding the heating element and can be used to determine whether the air surrounding the heating element is exceeding a predetermined threshold temperature. If the air becomes too hot, the thermocouple breaks a circuit, which thereby turns the dryer off and prevents the dryer from operating. The temperature of the air surrounding the heating element is monitored because the air surrounding the heating element often becomes too hot for safe operation when an exhaust conduit contains a blockage. Blockages in the exhaust conduits are dangerous because the blockages can cause the heating element to overheat and ignite lint near the heating element.
Many exhaust hoses for clothes dryers are incorrectly installed such that the exhaust hoses have internal diameters that are too small or are restrained. Such configurations accelerate lint collection on inside surfaces of the exhaust hoses, which may eventually result in partial or total blockage of the exhaust conduit. Such accumulation of lint may occur relatively quickly or over a longer period, such as a few years, and may go unnoticed by a homeowner. Such conditions are extremely dangerous.
While the conventional configuration of locating a thermocouple proximate to heating elements in a dryer has undoubtedly prevented many fires, dryers having this configuration remain susceptible to fires. In fact, dryers remain one of the most dangerous household appliances. Thus, a need exists for a system for improving the safety of clothes dryers.
SUMMARY OF THE INVENTION
This invention relates to a restriction sensor system usable with a clothes dryer for identifying blockages in an exhaust conduit downstream of a lint screen in an effort to prevent dangerous conditions and fires. The blockages may be found in the exhaust conduit located inside of or outside of a clothes dryer. The restriction sensor system may include a pressure sensing device for sensing the air pressure in an exhaust conduit of a clothes dryer downstream of a lint screen and creating an alert message when the air pressure on the exhaust conduit exceeds a pre-established threshold air pressure. The pressure sensing device may be formed from a body configured to be coupled to an exhaust conduit of a clothes dryer and may have at least one cavity for containing a diaphragm. The pressure sensing device may also include a diaphragm capable of reacting to relatively small changes in air pressure in the exhaust conduit. The pressure sensing device may also include a sensor for sensing the reactions of the diaphragm. In one embodiment, the sensor may be coupled to the diaphragm. The pressure sensing device may also include an orifice in the body for admitting a gas, such as air, from the exhaust conduit into the cavity of the pressure sensing device.
The restriction sensor system may also include one or more indicators for indicating that the pressure sensing device has identified that the air pressure in the exhaust conduit of the clothes dryer has exceeded a threshold air pressure. The indicator may be capable of generating a visual alert or an audible alert, or both. The indicator may be configured to be attached to a control panel of a clothes dryer or in another location on a clothes dryer.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the presently disclosed invention and, together with the description, disclose the principles of the invention.
FIG. 1 is a perspective view with a partial cut away of a clothes dryer having a restriction sensor system.
FIG. 2 is a perspective view of a pressure sensing device usable in the restriction sensor system of FIG. 1 .
FIG. 3 is an exploded view of the pressure sensing device of FIG. 2 .
FIG. 4 is a perspective view of another embodiment of a pressure sensing device.
FIG. 5 is a side view of another embodiment of a pressure sensing device.
FIG. 6 is a top view of the pressure sensing device shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1-4, this invention is a restriction sensor system 10 for use with an exhaust system 12 of a clothes dryer 14 . Restriction sensor system 10 may be capable of determining whether an exhaust conduit 16 downstream of a lint screen contains a blockage, which could potentially cause unsafe conditions and lead to a fire. Exhaust conduit 16 may include portions of the exhaust system located inside of or outside of clothes dryer 14 , or both. Restriction sensor system 10 may include a pressure sensing device 18 and an indicator 20 for indicating that pressure sensing device 18 has sensed an air pressure exceeding a threshold pressure in exhaust conduit 16 of clothes dryer 14 .
Pressure sensing device 18 may be capable of determining whether the air pressure in exhaust conduit 16 has exceeded a threshold air pressure, which may indicate that a blockage exists. In one embodiment, pressure sensing device 18 may be a differential pressure monitoring device, as available from Veris Industries in Portland, Oreg. and shown in FIGS. 5 and 6. Exhaust conduit 16 is a conduit downstream of a lint screen, or if a dryer does not contain a lint screen, exhaust conduit 16 is a conduit extending from tumbler 36 to an exit port venting air from clothes dryer 14 . Pressure sensing device 18 may be formed from a body 22 configured to fit into exhaust conduit 16 . Body 22 may contain one or more cavities 24 for containing a diaphragm, as shown in FIG. 3 . In at least one embodiment, a diaphragm 26 is positioned in cavity 24 . Diaphragm 26 may be positioned so that a plane 27 in which diaphragm 26 rests is generally orthogonal to a general direction in which air is flowing and striking diaphragm 26 . Diaphragm 26 may be a thin film capable of reacting to small changes in pressure.
Cavity 24 may be in communication with one or more orifices 28 in body 22 . Orifice 28 may admit air found in exhaust conduit 16 , into cavity 24 . In another embodiment, orifice 28 may be coupled to a conduit 29 for admitting air found in exhaust conduit 16 . Orifice 28 may have any size appropriate for admitting a gas into cavity 24 . Orifice 28 is configured to inhibit contamination by lint or other debris. In one embodiment, orifice 28 and conduit 29 may form a pitot tube or static tube.
Body 22 may also have a sensor 30 coupled to diaphragm 26 . Sensor 30 may be capable of sensing changes in position of diaphragm 26 that may be caused by changes in pressure in exhaust conduit 16 . Sensor 30 may also be capable of measuring strain in diaphragm 26 . Sensor 30 may be formed from solid-state feedback circuitry.
Body 22 may further include a fin 32 , as shown in FIG. 4, housing orifice 28 . Fin 32 may be coupled to a bottom side 40 of body 22 . Fin 32 may be sized to accommodate orifice 28 and may have an aerodynamically efficient exterior surface. Fin 32 may include a curved edge 42 extending from the bottom side 40 of body 22 to orifice 28 . In another embodiment, body 32 may not include fin 32 , but instead include only conduit 29 , as shown in FIG. 2 . Conduit 29 may have any size appropriate for admitting air into cavity 24 . In one embodiment, restriction sensor system 10 may be configured to position orifice 10 in exhaust conduit 16 so that orifice 28 faces downstream. However, this invention is not limited to positioning orifice 28 in this position. Rather, in another embodiment, restriction sensor system 10 may be positioned so that orifice 28 faces upstream.
Pressure sensing device 18 may include one or more indicators 20 for indicating that the exhaust conduit 16 has undergone an increase in air pressure that may be caused by, for instance and not by way of limitation, a blockage in exhaust conduit 16 . Indicator 20 may emit a visual alert or an audible alert, or both. Indicator 20 may be a light emitting device (LED) or other visually alerting device. Indicator 20 may also be a speaker, buzzer, or other noise making device. Indicator 20 may be configured to be attached to a control panel 34 of clothes dryer 14 . Indicator 20 may be coupled to sensor 30 using one or more electricity conducting wires 38 . Wires 38 may be connected to connectors 44 .
In another embodiment, restriction sensor system 10 may include pressure sensing device 18 including diaphragm 26 , as shown in FIGS. 5 and 6, that is configured to be coupled to exhaust conduit 16 of clothes dryer 14 using a conduit rather than coupling the pressure sensing device 18 directly to exhaust conduit 16 . Diaphragm 26 may be a diaphragm having model number RSS-495 that is available from Cleveland Controls of Cleveland, Ohio. The conduit may be coupled to diaphragm 26 at an inlet 35 using connection mechanisms such as, but not limited to, barbs and other devices. The conduit may be mounted directly to a port in exhaust conduit 16 . Alternatively, the conduit may be mounted a device or have an end with a fin 32 . In this embodiment, restriction sensor system 10 may also include sensor 30 in communication with diaphragm 26 and one or more indicators 20 for indicating the pressure in exhaust conduit 16 of clothes dryer 14 . Sensor 30 may be, but is not limited to, a snap-acting switch.
Restriction sensor system 10 is capable of being installed on any clothes dryer with little modification during a manufacturing process or after a clothes dryer has been completely assembled. The clothes dryer may have a tumbler 36 for containing clothes, a heating element for heating air, a fan for blowing air across the clothes in tumbler 36 , an exhaust conduit 16 for removing heated air, a control panel 34 , and a motor for rotating tumbler 36 . Pressure sensing device 18 may be coupled to exhaust conduit 16 downstream of either a lint screen, or if the clothes dryer does not have a lint screen, down stream of the point at which exhaust conduit 16 couples to tumbler 36 .
During operation of clothes dryer 14 , lint and other debris is collected with a lint screen. However, lint and other debris often pass through the lint screen and collects in exhaust conduit 16 . Accumulation of lint and other debris in exhaust conduit 16 is a fire hazard. When clothes dryer 14 is operating, air pressure develops in exhaust conduit 16 . As debris collects in clothes dryer 14 , the air pressure in exhaust conduit 16 increases. As the air pressure increases, diaphragm 26 reacts to the change in air pressure. Sensor 30 senses the reaction of diaphragm 26 . When the air pressure in exhaust conduit 16 exceeds a threshold pressure, sensor 30 causes indicator 20 to indicate that exhaust conduit 16 exceeds the threshold pressure. An increase in air pressure in the exhaust system of a clothes dryer may be caused by an increase in lint accumulation.
Indicator 20 may indicate that an air pressure in excess of a threshold air pressure has been observed by producing a blinking light, a light that is continuously turned on, a noise, such as, but not limited to, a buzzer, a voice that may give instructions on how to check the exhaust conduit, or others. In one embodiment, after sensor 30 determines that a threshold air pressure has been exceeded, indicator 20 remains actuated at all times when clothes dryer 14 is in use until the air pressure subsides to a level beneath the threshold air pressure. The threshold air pressure will vary depending on numerous factors, such as, but not limited to, the diameter of exhaust conduit 16 , the length of exhaust conduit 16 , the presence or absence of a cover on the end of exhaust conduit 16 and other factors. As a result, the threshold air pressure may vary.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention.
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A restriction sensor system for identifying the existence of blockages in exhaust conduits of clothes dryers. The restriction sensor system may include a pressure sensing device having a body configured to be coupled to an exhaust conduit of a clothes dryer. The pressure sensing device may be capable of determining changes in air pressure in the exhaust conduit. Once the air pressure present in the exhaust conduit exceeds a threshold air pressure, the pressure sensing device may send a signal to an indicator to generate an alarm, which may be a visual alarm or audible alarm, or both.
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[0001] This application claims priority under 35 U.S.C. 119 of U.S. Provisional 60/471,450, filed May 16, 2003. The entire contents of the prior application are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the treatment of bipolar disorder in a mammal, including a human. More specifically, the present invention is directed to the treatment in a mammal, including a human, of rapid-cycling bipolar disorder, and for the treatment of symptoms of bipolar disorder, such symptoms selected from the group consisting of acute mania and depression. The present invention is also directed to a treatment method for effecting mood stabilization in a person afflicted with bipolar disorder. The present invention further relates to a method of preventing relapse into bipolar episodes in a person afflicted with bipolar disorder. The present invention is further directed to the treating suicidal thoughts and tendencies in a person afflicted with bipolar disorder. The present invention also relates to new therapeutic uses for piperazinyl-heterocyclic compounds of the formula I, as defined below, for example ziprasidone.
BACKGROUND OF THE INVENTION
[0003] The piperazinyl-heterocyclic compounds of formula I of this invention are disclosed in U.S. Pat. Nos. 4,831,031 and 4,883,795, both of which are assigned in common with the present application. Certain treatments for such compounds are disclosed in U.S. Pat. Nos. 6,127,373, 6,245,766, and 6,387,904, all of which are also assigned in common with the present application. The patents listed in this paragraph are incorporated by reference in their entireties into the present disclosure.
SUMMARY OF THE INVENTION
[0004] The present invention relates to the use of piperazinyl-heterocyclic compounds of the formula I, as defined below, in methods for the treatment of bipolar disorder in a mammal, including a human. Specifically, the present invention is directed to a method for the treatment in a mammal, including a human, of rapid-cycling bipolar disorder, a method for the treatment of symptoms of bipolar disorder, such symptoms selected from the group consisting of acute mania and depression; a method for a treatment that effects mood stabilization in a person afflicted with bipolar disorder; a method for a treatment that prevents relapse into bipolar episodes in a person afflicted with bipolar disorder; a method for the treatment of suicidal thoughts and tendencies in a person afflicted with bipolar disorder; such treatments comprising administering a pharmaceutically effective amount of a compound of the formula I:
or a pharmaceutically acceptable acid addition salt thereof, wherein Ar is benzoisothiazolyl or an oxide or dioxide thereof each optionally substituted by one fluoro, chloro, trifluoromethyl, methoxy, cyano, nitro or naphthyl optionally substituted by fluoro, chloro, trifluoromethyl, methoxy, cyano or nitro; quinolyl; 6-hydroxy-8-quinolyl; isoquinolyl; quinazolyl; benzothiazolyl; benzothiadiazolyl; benzotriazolyl; benzoxazolyl; benzoxazolonyl; indolyl; indanyl optionally substituted by one or two fluoro, 3-indazolyl optionally substituted by 1-trifluoromethylphenyl; or phthalazinyl; n is 1 or 2; and X and Y together with the phenyl to which they are attached form quinolyl; 2-hydroxyquinolyl; benzothiazolyl; 2-aminobenzothiazolyl; benzoisothiazolyl; indazolyl; 2-hydroxyindazolyl; indolyl; spiro; oxindolyl optionally substituted by one to three of (C 1 -C 3 ) alkyl, or one of chloro, fluoro or phenyl, said phenyl optionally substituted by one chloro or fluoro; benzoxazolyl; 2-aminobenzoxazolyl; benzoxazolonyl; 2-aminobenzoxazolinyl; benzothiazolonyl; bezoimidazolonyl; or benzotriazolyl.
[0006] In one specific embodiment, the present invention is directed to a method for the treatment in a mammal, including a human, of rapid-cycling bipolar disorder, a method for the treatment of symptoms of bipolar disorder, such symptoms selected from the group consisting of acute mania and depression; a method for a treatment that effects mood stabilization in a person afflicted with bipolar disorder; a method for a treatment that prevents relapse into bipolar episodes in a person afflicted with bipolar disorder; a method for the treatment of suicidal thoughts and tendencies in a mammal afflicted with bipolar disorder; such treatments comprising administering to said mammal an effective amount of ziprasidone: 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)chlorooxindole, or a pharmaceutically acceptable acid addition salt thereof.
[0007] The term “ziprasidone”, as used herein, unless otherwise indicated, encompasses the free base of the compound ziprasidone (named in the preceding paragraph) and all pharmaceutically acceptable salts thereof.
[0008] Pharmaceutically acceptable addition salts include, but are not limited to, salts of the compounds of formula 1, such as mesylate, esylate, and hydrochloride, among others, and may also include polymorphic forms of such salts.
[0009] In yet another aspect of the present invention, the treatments described above improve the condition of a person afflicted with bipolar disorder, or as the case may be the symptoms associated with bipolar disorder as described above, within about 96 hours from the first administration of a compound of formula 1, such as for example, Ziprasidone.
[0010] However, such improvements can be realized more rapidly, that is within about 24 to about 96 hours after administering a compound of formula 1, such as for example, Ziprasidone.
[0011] The term “treating”, as used herein, refers to reversing, alleviating, inhibiting the progress of, or preventing the disorder or condition to which such term applies, or one or more symptoms of such disorder or condition. The term “treatment”, as used herein, refers to the act of treating, as “treating” is defined immediately above.
[0012] The term “pharmaceutically effective amount”, as used herein, refers to an amount of the compound sufficient to treat, in a mammal, including a human, as the case may be, rapid-cycling bipolar disorder, symptoms of bipolar disorder selected from the group consisting of acute mania and depression; to effect mood stabilization; to prevent relapse into bipolar episodes; and to a treat suicidal thoughts and tendencies.
[0013] As provided in the DSM-IV, the specifier of bipolar disorder with rapid cycling can be applied to Bipolar I Disorder or Bipolar II Disorder. The essential feature of a rapid-cycling Bipolar Disorder is the occurrence of four or more mood episodes during the previous 12 months.
[0014] The “symptoms of bipolar disorder selected from the group consisting of acute mania and depression” refer to, respectively, one or more symptoms that may be associated with a manic episode or a depressive episode, as the case may be, of bipolar disorder.
[0015] “Mood stabilization”, as used herein, refers to the suppression of manic symptoms and depressive symptoms in order to maintain a euthymic state in the subject of the treatment.
[0016] As used herein, the term “relapse prevention” refers to preventing the recurrence of a kind of episode in a subject who previously experienced at least one of that same kind of episode. An example of “relapse prevention” is preventing a recurrence of a manic episode in a subject who previously experienced one or more manic episodes.
[0017] The treatment of “suicidal thoughts and tendencies” refers to the suppression of suicidal ideation in a subject afflicted with bipolar disorder, with the further goal of suppressing suicide attempts.
[0018] In practicing the inventive methods, the treatment preferably comprise administering a compound of formula I wherein Ar is benzoisothiazolyl and n is 1.
[0019] Preferably X and Y, together with the phenyl to which they are attached, form an oxindole optionally substituted by chloro, fluoro or phenyl.
[0020] In yet another, more specific embodiment of the inventive methods, the compound administered is one wherein Ar is naphthyl and n is 1.
[0021] The psychiatric disorders and conditions referred to herein are known to those of skill in the art and are defined in art-recognized medical texts such as the Diagnostic and Statistical Manual of Mental Disorders, Fourth Edition, American Psychiatric Association, 1994 (DSM-IV), which is incorporated herein by reference in its entirety.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The piperazinyl-heterocyclic compounds of formula I can be prepared by one or more of the synthetic methods described and referred to in U.S. Pat. Nos. 4,831,031 and 4,883,795. U.S. Pat. Nos. 4,831,031 and 4,883,795 are incorporated herein by reference in their entireties.
[0023] The compounds of formula I may be prepared by reacting piperazines of formula II with compounds of formula III as follows:
wherein Hal is fluoro, chloro, bromo or iodo. This coupling reaction is generally conducted in a polar solvent such as a lower alcohol, for instance ethanol, dimethylformamide or methylisobutylketone, and in the presence of a weak base such as a tertiary amine base, for instance triethylamine or diisopropylethylamine. Preferably, the reaction is in the further presence of a catalytic amount of sodium iodide, and a neutralizing agent for hydrochloride such as sodium carbonate. The reaction is preferably conducted at the reflux temperature of the solvent used. The piperazine derivatives of formula II may be prepared by methods known in the art. For instance, preparation may be effected by reacting an arylhalide of the formula ArHal wherein Ar is as defined above and Hal is fluoro, chloro, bromo or iodo, with piperazine in a hydrocarbon solvent such as toluene at about room temperature to reflux temperature for about half an hour to 24 hours. Alternatively, the compounds of formula II may be prepared by heating an amino-substituted aryl compound of the formula ArNH 2 wherein Ar is as defined above with a secondary amine to allow cyclization to form the piperazine ring attached to the aryl group Ar.
[0025] The compounds of formula III may be prepared by known methods. For instance, compounds (III) may be prepared by reacting a halo-acetic acid or halo-butyric acid wherein the halogen substituted is fluoro, chloro, bromo or iodo with a compound of the formula IV as follows:
wherein X and Y are as defined above and m is 1 or 3. The compounds (V) are then reduced, e.g. with triethylsilane and trifluoroacetic acid in a nitrogen atmosphere, to form compounds (111).
[0027] When Ar is the oxide or dioxide of benzoisothiazolyl, the corresponding benzoisothiazolyl is oxidized under acid conditions at low temperatures. The acid used is advantageously a mixture of sulphuric acid and nitric acid.
[0028] The pharmaceutically acceptable acid addition salts of the compounds of formula I may be prepared in a conventional manner by treating a solution or suspension of the free base (I) with about one chemical equivalent of a pharmaceutically acceptable acid. Conventional concentration and recrystallization techniques may be employed in isolating the salts. Illustrative of suitable acids are acetic, lactic, succinic, maleic, tartaric, citric, gluconic, ascorbic, benzoic, cinnamic, fumaric, sulfuric, phosphoric, hydrochloric, hydrobromic, hydroiodic, sulfamic, sulfonic such as methanesulfonic, benzenesulfonic, and related acids.
[0029] Compounds of formula I, and their pharmaceutically acceptable salts (referred to collectively hereinafter, as “the active compounds of this invention”), can be administered to a human subject either alone, or, preferably, in combination with pharmaceutically-acceptable carriers or diluents, in a pharmaceutical composition. Such compounds can be administered orally or parenterally. Parenteral administration includes especially intravenous and intramuscular administration. Treatments of the present invention may be delivered in an injectable depot formulation, such as the depot formulations disclosed in U.S. Provisional Patent Application No. 60/421,295 filed on Oct. 25, 2002, which application is incorporated herein by reference in its entirety.
[0030] Additionally, in a pharmaceutical composition comprising an active compound of this invention, the weight ratio of active ingredient to carrier will normally be in the range from 1:6 to 2:1, and preferably 1:4 to 1:1. However, in any given case, the ratio chosen will depend on such factors as the solubility of the active component, the dosage contemplated and the precise route of administration.
[0031] For oral use in treating psychiatric conditions whose manisfestations include psychiatric symptoms or behavioral disturbance, the active compounds of this invention can be administered, for example, in the form of tablets or capsules, or as an aqueous solution or suspension. In the case of tablets for oral use, carriers that can be used include lactose and cornstarch, and lubricating agents, such as magnesium stearate, can be added. For oral administration in capsule form, useful diluents are lactose and dried cornstarch. When aqueous suspensions are required for oral use, the active ingredient can be combined with emulsifying and suspending agents. If desired, certain sweetening and/or flavoring agents can be added. For intramuscular, parenteral and intravenous use, sterile solutions of the active ingredient can be prepared, and the pH of the solutions should be suitably adjusted and buffered. For intravenous use, the total concentration of solutes should be controlled to render the preparation isotonic.
[0032] When an active compound of this invention is to be used in a human subject to treat psychiatric conditions whose manisfestations include psychiatric symptoms or behavioral disturbance, the prescribing physician will normally determine the daily dosage. Moreover, the dosage will vary according to the age, weight and response of the individual patient as well as the severity of the patient's symptoms. However, in most instances, an effective amount for treating the psychiatric conditions described herein, will be a daily dosage in the range from about 0.5 to about 500 mg, more specifically about 10 mg a day to about 200 mg a day, relatively more specifically about 20 mg a day to about 180 mg a day, relatively still more specifically about 30 mg a day to about 170 mg a day, and relatively even more specifically from about 40 to about 160 mg a day, in single or divided doses, orally or parenterally. In some instances it may be necessary to use dosages outside these limits. The receptor binding and neurotransmitter uptake inhibition profile for Ziprasidone, 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)chlorooxindole, was described in The Journal of Pharmacology and Experimental Therapeutics, 275, 101-113 (1995), which is incorporated herein by reference in its entirety. A summary of its affinity for various receptors in the central nervous system tissue is presented in Table 1.
TABLE 1 Ziprasidone Receptor (Ligand) DA D1([ 3 H]SCH23390) 6.28 + 0.17 (3) DA D2([ 3 H]spiperone) 8.32 + 0.04 (6) DA D3([ 3 H]raclopride) 8.14 + 0.03 (3) DA D4[ 3 H]spiperone) 7.49 + 0.11 (3) 5-HT2A([ 3 H]ketanserin) 9.38 + 0.03 (5) 5-HT1A([ 3 H]-80H-DPAT) 8.47 + 0.05 (4) 5-HT-2C- ([ 3 H]mesulergine) 8.88 + 0.05 (6) 5-HT1D- ([ 3 H]-5-HT) 8.69 + 0.04 (6) Alpha-1 ([ 3 H]prazosin) 7.98 + 0.03 (3) Histamine H1 7.33 + 0.07 (3) ([ 3 H]mepyramine) Neurotransmitter Reuptake Blockade: Norpinephrine 7.30 + 0.01 (4) 5-HT 7.29 + 0.06 (3) DA 6.58 + 0.02 (3)
[0033] The following examples illustrate methods of preparing various compounds of formula I.
EXAMPLE 1
[0034] 6-(2-(4-(1-Naphthyl)piperazinyl)ethyl)-benzoxazolone
[0035] A. To a 500 ml three-necked round-bottomed flask equipped with mechanical stirrer and nitrogen inlet were added 200 grams of polyphosphoric acid, 13.51 grams (0.1 mole) of benzoxazolone, and 13.89 g (0.1 mole) of bromoacetic acid. The reaction was heated with stirring at 115° C. for 2.5 hours and poured into 1 kg ice. The mixture was stirred mechanically for 1 hour to form a purple solid, which was then filtered off and washed with water. The solid was slurried with acetone for 30 minutes, a small amount of purple solid filtered off, and the brown filtrate evaporated. The resulting dark brown gum was slurried with 150 ml ethanol for 30 minutes, and the brown solid filtered off and washed with ethanol. This solid has a m.p. of 192°-194° C.
[0036] The solid (6.6 grams, 0.0257 mole) was placed in a 100 ml three-necked round-bottomed flask equipped with magnetic stirrer, dropping funnel, thermometer, and nitrogen inlet and 19.15 ml (0.257 mole) of trifluoroacetic acid added. Triethylsilane (9.44 ml, 0.0591 mole) was added dropwise to the stirring slurry over 30 minutes. The reaction was stirred overnight at room temperature, then poured into 150 grams ice. The mixture was stirred for 15 minutes, and the brown gum filtered off. The gum was dissolved in 100 ml ethyl acetate, and 125 ml cyclohexane added, giving a brown precipitate, which was filtered and washed with cyclohexane. The filtrate was evaporated and the resulting yellow solid slurried with 50 ml isopropyl ether the pale yellow solid was filtered off and dried to give 2.7 g 6-(2-bromoethyl)-benzoxazolone (11% yield for two steps), m.p. 148′-151° C.
[0037] B. To a 100 ml round-bottomed flask equipped with magnetic stirrer, condenser, and nitrogen inlet were added 0.618 g (2.10 mmol) of N-(1-naphthyl)piperazine 0.472 g (1.95 mmol) of 6-(2-bromoethyl)-benzoxazolone, 0.411 ml (2.92 mmol) of triethylamine, 50 ml ethanol, and a catalytic amount of sodium iodide. The reaction was refluxed for 3 days, cooled, and evaporated to a brown gum. The gum was partitioned between 50 ml water and 75 ml methylene chloride, the pH adjusted with aqueous 1 N sodium hydroxide solution, and a little methanol added to facilitate phase separation. The methylene chloride layer was dried over sodium sulfate and evaporated, then chromatographed on silica gel. Fractions containing the product were combined and evaporated, the residue taken up in ethyl acetate, treated with hydrochloride gas, and the resulting hydrochloride salt of the product filtered off to give the while solid title compound, m.p. 282°-285° C., 213 mg (23% yield).
EXAMPLE 2
[0038] 6-(2-(4-(1-Naphthyl)piperazinyl)ethyl)-benzimidazolone
[0039] A. To a 500 ml three-necked round-bottomed flask equipped with mechanical stirrer and nitrogen inlet were added 100 grams of polyphosphoric acid, 6.7 grams (0.05 mole) of benzoxazolone, and 6.95 grams (0.05 mole) of bromoacetic acid. The reaction was heated with stirring at 115° C. for 1.5 hours and poured into 1 kg ice. The mixture was stirred mechanically for 1 hour to form a gray solid, which was then filtered off and washed with water. The solid was slurried with acetone for 30 minutes, a small amount of purple solid filtered off, and the brown filtrate evaporated. The resulting dark brown gum was taken up in ethyl acetate/water, and the organic layer washed with water and brine, dried, and evaporated to solid, 6.5 grams (51%). NMR (d, DMSO-d 6 ): 5.05 (s, 2H), 7.4 (m, 1H), 7.7-8.05 (m, 2H).
[0040] The solid (6.0 grams, 0.0235 mole) was placed in a 100 ml three-necked round-bottomed flask equipped with magnetic stirrer, dropping funnel, thermometer, and nitrogen inlet and 18.2 ml (0.235 mole) of trifluoroacetic acid added. Triethylsilane (8.64 ml, 0.0541 mole) was added dropwise to the stirring slurry over 30 minutes. The reaction was stirred overnight at room a temperature, then poured into 150 grams ice. The mixture was stirred for 14 minutes, and the pink solid 6-(2-bromoethyl)-benzimidazolone filtered off to give 5.0 grams (42% yield for two steps), m.p. 226°-220° C.
[0041] B. To a 100 ml round-bottomed flask equipped with magnetic stirrer, condenser, and nitrogen inlet were added 2.64 grams (12.4 mmol) of N-(1-naphthyl)-piperazine, 3.0 grams (12.4 mmol) of 6-(2-bromoethyl)-benzimidazolone, 1.31 grams (12.4 mmol) sodium carbonate, 50 ml methylisobutylketone, and a catalytic amount of sodium iodide. The reaction was refluxed for 3 days, cooled, and evaporated to a brown gum. The gum was partitioned between 50 ml water and 75 ml ethyl acetate, and the ethyl acetate layer washed with brine, dried over sodium sulfate, and evaporated, then chromatographed on silica gel. Fractions containing the product were combined and evaporated, the residue taken up in tetrahydrofuran, treated with hydrochloric acid gas, and the resulting hydrochloride salt of the product filtered off to give a white solid, m.p. 260°-262° C., 716 mg (14% yield).
EXAMPLE 3
[0042] 6-(2-(4-(8-Quinolyl)piperazinyl)ethyl)-benzoxazolone
[0043] To a 35 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 0.36 grams (1.5 mmol) of 6-bromoethyl benzoxazolone, 0.32 grams (1.5 mmol) of 8-piperazinyl quinoline, 0.2 grams (1.9 mmol) of sodium carbonate, 50 mg of sodium iodide, and 5 ml of ethanol. The reaction was refluxed for 20 hours, cooled, diluted with water, and the pH adjusted to 4 with 1 N Sodium hydroxide, and the product extracted into ethyl acetate. The ethyl acetate layer was washed with brine, dried, and evaporated to give 0.3 grams of a yellow oil. The oil was dissolved in ethyl acetate, ethyl acetate saturated with hydrochloric acid gas added, and the mixture concentrated to dryness. The residue was crystallized from isopropanol to give 0.18 grams (32%) of a yellow salt, m.p. 2000 NMR (d, CDCl 3 ): 2.74 (m, 2H), 2.89 (m, 6H), 3.44 (m, 4H), 6.76-7.42 (m, 7H), 8.07 (m, 1H), 8.83 (m, 1H).
EXAMPLE 4
[0044] 6-(2-(4-(6-Quinolyl)piperazinyl)ethyl)-benzoxazolone
[0045] To a 35 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 0.36 grams (1.5 mmol) of 6bromoethylbenzoxazolone, 0.32 g (1.5 mmol) of 8-piperazinylquinazoline, 0.85 grams (8.0 mmol) of sodium carbonate, 2 mg of sodium iodide, and 35 ml of ethanol. The reaction was refluxed for 3 days, cooled, diluted with water, and the pH adjusted to 4 with 1 N HCl. The aqueous layer was separated, the pH adjusted to 7 with 1 N Sodium hydroxide, and the product extracted into ethyl acetate. The ethyl acetate layer was washed with brine, dried, and evaporated to give 1.3 grams of a yellow oil. The oil was crystallized form chloroform (1.1 g), dissolved in ethyl acetate, ethyl acetate saturated with hydrochloric acid gas added, and the mixture concentrated to dryness. The residue gave 0.9 grams (58%) of a yellow salt, m.p. 200° C. NMR (d, CDCl 3 ):
[0046] 2.72 (m, 6H), 2.86 (m, 2H), 3.83 (m, 4H), 6.9-7.9 (m, 7H), 8.72 (s, 1H).
EXAMPLE 5
[0047] 6-(2-(4-(4-Phthalazinyl)piperazinyl)ethyl)-benzoxazolone
[0048] To a 35 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 1.13 grams (4.7 mmol) of 6-bromoethyl benzoxazolone, 1.0 gram (4.7 mmol) of 4-piperazinyl phthalazine, 0.64 grams (6.0 mmol) of sodium carbonate, and 30 ml of ethanol. The reaction was refluxed for 20 hours, cooled, diluted with water, and the pH adjusted to 4 with 1 N HCl. The aqueous layer was separated, the pH adjusted to 7 with 1 N Sodium hydroxide, and the product extracted into ethyl acetate. The ethyl acetate layer was washed with brine, dried, and evaporated to give 0.5 grams of a red oil. The oil was chromatographed on silica gel using chloroform/methanol as eluent to give 0.2 grams of a pink oil. The oil was dissolved in ethyl acetate, ethyl acetate saturated with hydrochloric acid gas added and the mixture concentrated to give 0.37 grams (11%) of a yellow salt, m.p. 200° C. NMR (d, CDCl 3 ): 2.78 (m, 2H), 2.88 (m, 6H), 3.65 (m, 4H), 7.0-8.1 (m, 7H), 9.18 (s, 1H).
EXAMPLE 6
[0049] 6-(2-(4-(4-Methoxy-1-naphthyl)piperazinyl)ethyl)-benzoxazolone
[0050] To a 35 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 0.24 grams (1.0 mmol) of 6-bromoethylbenzoxazolone, 0.24 grams (1.0 mmol) of 4-methoxy-1-piperazinylnaphthalene, 0.13 grams (1.2 mmol) of sodium carbonate, and 25 ml of ethanol. The reaction was refluxed for 36 hours, cooled, diluted with water, and the product extracted into ethyl acetate. The ethyl acetate layer was washed with brine, dried, and evaporated to give 0.49 grams of a yellow oil. The oil was chromatographed on silica gel using chloroform as eluent to give 0.36 grams of yellow crystals. The solid was dissolved in ethyl acetate, ethyl acetate saturated with hydrochloric acid gas added, and the mixture concentrated to dryness to give 0.26 grams (55%) of white salt crystals, m.p. 2000 C. NMR (d, CDCl 3 ): 2.8-3.2 (m, 12H), 4.01 (s, 3H), 6.7-7.6 (m, 7H), 8.26 (m, 2H).
EXAMPLE 7
[0051] 6-(2-(4-(5-Tetralinyl)piperazinyl)ethyl)-benzoxazolone
[0052] To a 35 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 1.0 gram (3.9 mmol) of 6-bromoethylbenzoxazolone, 0.85 grams (3.9 mmol) of 5-piperazinyltetralin, 0.4 grams (3.9 mmol) of sodium carbonate, 2 mg of sodium iodide, and 30 ml of isopropanol. The reaction was refluxed for 18 hours, cooled, evaporated to dryness, and the residue dissolved in ethyl acetate/water. The pH was adjusted to 2.0 with 1 N HCl, and the precipitate which had formed collected by filtration. The precipitate was suspended in ethyl acetate/water, the pH adjusted to 8.5 with 1 N Sodium hydroxide, and the ethyl acetate layer separated. The ethyl acetate layer was washed with brine, dried, and evaporated to give 0.7 grams of a solid. The solid was dissolved in ethyl acetate, ethyl acetate saturated with hydrochloric acid gas added, and the mixture concentrated to dryness to give 0.70 grams (40%) of a yellow salt, m.p. 200° C. NMR (d, CDCl 3 ): 1.9 (m, 4H), 2.95 (m, 16H), 6.8-7.2 (m, 6H).
EXAMPLE 8
[0053] 6-(2-(4-(6-Hydroxy-8-quinolyl)piperazinyl)ethyl)-benzoxazolone
[0054] To a 35 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 0.84 grams (3.5 mmol) of 6-bromoethylbenzoxazolone, 0.80 grams (3.5 mmol) of 6-hydroxy-8-piperazinyl quinoline, 0.37 grams (3.5 mmol) of sodium carbonate, 2 mg of sodium iodide, and 30 ml of isopropanol. The reaction was refluxed for 18 hours, cooled, evaporated, and the residue dissolved in ethyl acetate/water. The pH was adjusted to 2.0 with 1 N HCl, and the phases separated. The aqueous phase was adjusted to pH 8.5 and extracted with ethyl acetate. The ethyl acetate layer was washed with brine, dried, and evaporated to give 0.33 grams of a yellow solid. The solid was dissolved in ethyl acetate, ethyl acetate saturated with hydrochloric acid gas added, and the mixture concentrated to dryness. The residue was crystallized from isopropanol to give 0.32 grams (20%) of a yellow salt, m.p. 200° C. NMR (d, CDCl 3 ): 2.8 (m, 8H), 3.4 (m, 4H), 6.7-7.3 (m, 7H), 7.7-7.9 (m, 1H).
EXAMPLE 9
[0055] 6-(2-(4-(1-(6-Fluoro)naphthyl)piperazinyl)ethyl)-benzoxazolone
[0056] A. To a round-bottomed flask equipped with condenser and nitrogen inlet were added 345 ml (3.68 mol) of fluorebenzene and 48 grams (0.428 mol) of furoic acid. To the stirring suspension was added in portion 120 grams (0.899 mol) of aluminum chloride. The reaction was then stirred at 950 C. for 16 hours and then quenched by addition to ice/water/1 N HCl. After stirring 1 hour, the aqueous layer was decanted off, and benzene and a saturated aqueous solution of sodium bicarbonate added. After stirring 1 hour, the layers were separated, the aqueous layer washed with benzene, acidified, and extracted into ethyl acetate. The ethyl acetate layer was washed with water and brine, dried over sodium sulfate, and evaporated to a solid. The solid was triturated with isopropyl ether to give 5.0 grams (6.1%) of white solid 6-fluoro-1-naphthoic acid, NMR (d, DMSO-d 6 ): 7.0-8.0 (m, 5H), 8.6 (m, 1H).
[0057] B. To a 125 ml round-bottomed flask equipped with condenser, addition funnel, and nitrogen inlet were added 5.0 grams (26.3 mmol) of 6-fluoro-1-naphthoic acid and 50 ml acetone. To the stirring suspension were added dropwise 6.25 ml (28.9 mmol) of diphenyl phosphoryl azide and 4 ml (28.9 mmol) of triethylamine. The reaction was refluxed 1 hour, poured into water/ethyl acetate, and filtered. The filtrate was washed with water and brine, dried over sodium sulfate, and evaporated. The residue was further treated with hydrochloric acid to form the hydrochloride salt and then liberated with sodium hydroxide to afford the free base 6-fluoro-1-amino-naphthalene as an oil, 1.0 gram (24%).
[0058] C. To a 125 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 1.0 gram (6.21 mmol) of 6-fluoro-1-amino naphthalene, 1.8 grams (7.76 mmol) of N-benzyl bis(2-chloroethyl)amine hydrochloride, 3.3 ml (19.2 mmol) of diisopropylethylamine, and 50 ml isopropanol. The reaction was refluxed 24 hours, cooled, and evaporated to an oil. The oil was taken up in ethyl acetate, washed with water and brine, dried over sodium sulfate, and evaporated to an oil. The oil was chromatographed on silica gel using methylene chloride as eluent to afford 1.5 grams (75.5%) of an oil, 1-benzyl-4-(6-fluoronaphthyl)-piperazine.
[0059] D. To a 125 ml round-bottomed flask equipped with nitrogen inlet were added 1.5 grams (4.69 mmol) of 1-benzyl-4-(6-fluoronaphthyl)-piperazine, 1.2 ml (31.3 mmol) of formic acid, 3.0 grams 5% palladium on carbon, 50 ml ethanol. The reaction was stirred at room temperature for 16 hours, the catalyst filtered under N 2 , and the solvent evaporated. The oil, N-(1-(6-fluoro)naphthyl)-piperazine (0.420 grams, 39%), was used directly in the following step.
[0060] E. To a 100 ml round-bottomed flask equipped with magnetic stirrer, condenser, and nitrogen inlet were added 0.420 grams (1.83 mmol) of N-(1-naphthyl)piperazine, 0.440 grams (1.83 mmol) of 6-(2-bromoethyl)-benzoxazolone, 194 mg (1.83 mmol) of sodium carbonate, 50 ml methylisobutylketone, and a catalytic amount of sodium iodide. The reaction was refluxed for 3 days, cooled, and evaporated to a brown gum. The gum was partitioned between 50 ml water and 75 ml ethyl acetate, the pH adjusted with aqueous 1 N Sodium hydroxide solution, the layers separated, and the ethyl acetate layer washed with water and brine. The ethyl acetate layer was dried over sodium sulphate and evaporated, then chromatographed on silica gel. Fractions containing the product were combined and evaporated, the residue taken up in ether/methylene chloride, treated with hydrochloric acid gas, and the resulting hydrochloride salt of the product filtered off to give a white solid, m.p. 295°-300° C., 214 mg (22% yield).
EXAMPLE 10
[0061] 6-(4-(4-(1-Naphthyl)piperazinyl)butyl)-benzoxazolone
[0062] A. To a 500 ml round-bottomed flask equipped with mechanical stirrer and nitrogen inlet were added 200 grams polyphosphoric acid, 16.7 grams (0.1 mol) 4-bromobutyric acid, and 13.51 grams (0.1 mol) benzoxazolone. The reaction was heated at 115° C. for 1 hour and 60° C. for 1.5 hours. It was then poured onto ice, stirred for 45 minutes and the solid filtered and washed with water. The solid was suspended in acetone, stirred for 20 minutes, filtered, washed with petroleum ether, and dried to give 12.3 grams (43%) of white solid 6-(4-bromobutyryl)-benzoxazolone NMR (d, DMSO-d 6 ): 1.77 quin, 2H), 3.00 (t, 2H), 3.45 (t, 2H), 7.0-7.8 (m, 3H).
[0063] B. To a 100 ml three-necked round-bottomed flask equipped with dropping funnel, thermometer, and nitrogen inlet were added 10 grams (0.035 mol) 6-(4-bromobutyryl)-benzoxazolone and 26.08 ml (0.35 mol) trifluoroscetic acid. To the stirring suspension was added dropwise 12.93 ml (0.080 mol) triethylsilane, and the reaction stirred at room temperature for 16 hours. The reaction was then poured into water, and the resulting white solid filtered and washed with water. It was then suspended in isopropyl ether, stirred, and filtered to afford white solid 6-(4-trifluoroacetoxybutyl)-benzoxazolone, m.p. 100°-103° C., 10.47 grams (98.7%).
[0064] C. To a 250 ml round-bottomed flask equipped with nitrogen inlet were added 5.0 grams (0.0164 mol) 6-(trifluoroacetoxybutyl)-benzoxazolone, 100 ml methanol, and 1 gram sodium carbonate. The reaction was stirred at room temperature for 1 hour, evaporated, and the residue taken up in methylene chloride/methanol, washed with aqueous HCl, dried over sodium sulfate, and evaporated to white solid 6-(4-chlorobutyl)-benzoxazolone, m.p. 130°-133° C., 2.57 grams (75.7%).
[0065] E. To a 100 ml round-bottom flask equipped with condenser and nitrogen inlet were added 0.658 grams (3.10 mmol) of 6-(4-chlorobutyl)-benzoxazolone, 0.7 grams (3.10 mmol) of N-(1-naphthyl)piperazine, 0.328 grams sodium carbonate, 2 mg sodium iodide, and 50 ml isopropanol. The reaction was refluxed for 3 days, evaporated, taken up in methylene chloride, washed with water, dried over sodium sulfate, and evaporated. The residue was chromatographed on silica gel using ethyl acetate as eluent, and the product dissolved in acetone, precipitated with ethereal HCl, and the white solid filtered, washed with acetone, and dried to afford 6.76 grams (46.0%) of a white solid, m.p. 231°-233° C.
EXAMPLE 11
[0066] 6-(2-(4-(3-(N-(3-Trifluoromethyl)phenyl)indazolyl)-piperazinyl)ethyl)benzox azolone
[0067] To a 125 ml round-bottomed flask equipped with condenser were added 1.0 gram (2.89 mmol) of N-(3-tri-fluoromethylphenyl)indazolyl)piperazine, 0.70 grams (2.89 mol) of 6-(2-bromoethyl)benzoxazolone, 0.31 grams (2.89 mmol) of sodium carbonate, and 50 ml of methyl isobutyl ketone, and the mixture refluxed 18 hours. The reaction was cooled and partitioned between ethyl acetate and water. The ethyl acetate layer was isolated, washed with water and saturated aqueous sodium chloride solution, dried over sodium sulfate, and evaporated to an oil. The oil was chromatographed on silica gel using ethyl acetate/methylene chloride as eluent, and the product fractions collection and dissolved in ether, precipitated with hydrochloride gas, and the solid collected to give the hydrochloride salt of the title compound, m.p. 280°-282° C., 0.75 grams (47%).
EXAMPLE 12
[0068] 5-(2-(4-(1-Naphthyl)piperazinyl)ethyl)oxindole
[0069] A. To a 250 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 30.7 grams (230 mmol) aluminum chloride, 150 ml carbon disulfide, and 3.8 ml (48 mmol) chloroacetyl chloride. To the stirring mixture was added 5.0 grams (37 mmol) of oxindole portionwise over 15 minutes. The reaction was stirred a further 10 minutes, then refluxed 2 hours. The reaction was cooled, added to ice, stirred thoroughly, and the beige precipitate filtered, washed with water, and dried to afford 7.67 grams (97%) of 5-chloroacetyl-oxindole. NMR (d, DMSO-d 6 ): 3.40 (s, 2H), 5.05 (s, 2H), 6.8-7.9 (m, 3H).
[0070] B. To a 100 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 5.0 grams (23.9 mmol) of 5-chloroacetyl oxindole and 18.5 ml triflouroacetic acid. To the stirring solution was added 8.77 ml (54.9 mmol) of triethylsilane while cooling to prevent exotherm, and the reaction stirred 16 hours at room temperature. The reaction was then poured into ice water, stirred and the beige solid filtered, washed with water and hexane, and dried to give 5-(2-chloroethyl)oxindole, m.p. 168°-170° C., 3.0 grams (64%).
[0071] C. To a 50 ml round bottomed flask equipped with condenser and nitrogen inlet were added 370 mg (1.69 mmol) 5-(2-chloroethyl)oxindole, 400 mg (1.69 mmol) N-(1-naphthyl)piperazine hydrochloride, 200 mg (1.69 mmol) sodium carbonate, 2 mg sodium iodide, and 50 ml methylisobutylketone. The reaction was refluxed 24 hours, cooled, and evaporated. The residue was taken up in ethyl acetate, washed with water and brine, dried over sodium sulfate, and evaporated. The residue was chromatographed on silica gel with ethyl acetate, and the product fractions collected and evaporated to give a foam. The foam was dissolved in ether, treated with hydrochloric acid gas, and the precipitate collected, washed with ether, and dried to afford a white solid, m.p. 303°-305° C., 603 mg (84%).
EXAMPLE 13
[0072] 6-(2-(4-(4-(2-,1,3-Benzothiadiazolyl)piperazinyl)ethyl)-benzoxazolone
[0073] A. To a 125 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 2.0 grams (13.2 mmol) 4-amino-2,1,3-benzothiadiazole, 2.54 grams (13.2 mmol) mechlorethamine hydrochloride, 4.19 grams (39.6 mmol) sodium carbonate, 2 mg sodium iodide, and 50 ml ethanol. The reaction was refluxed 2 days, cooled, and evaporated. The residue was taken up in methylene chloride, washed in water, dried over sodium sulfate, and evaporated. The residue was chromatographed on silica gel using ethyl acetate/methanol as eluent, and the product fractions collected and evaporated to an oil of 4-(2,1,3-benzothiadiazolyl)-N-methylpiperazine, 628 mg (20%). NMR (d, CDCl 3 ): 2.5 (s, 3H), 2.8 (m, 4H), 3.6 (m, 4H), 6.8 (m, 1H), 7.5 (m, 2H).
[0074] B. To a 25 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 620 mg (2.64 mmol) of 4-(2,1,3-benzothiadiazolyl)-N-methylpiperazine, 0.224 ml (2.64 mmol) vinyl chloroformate, and 15 ml dichloroethane. The reaction was refluxed 16 hours, cooled, and evaporated. The residue was chromatographed on silica gel using methylene chloride/ethyl acetate as eluent, and the product fractions collected to give yellow solid 4-(2,1,3-benzothiadiazolyl)-N-vinyloxycarbonylpiperazine, 530 mg (69%). NMR (d, CDCl 3 ): 3.6 (m, 4H), 3.8 (m, 4H). 4.4-5.0 (m, 2H), 6.6-7.6 (m, 4H).
[0075] C. To a 50 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 530 mg (1.83 mmol) 4-(2,1,3-benzothiadiazolyl)-N-vinyloxycarbonylpiperazine and 25 ml ethanol, and the suspension saturated with hydrochloric acid gas. The reaction was refluxed 2.75 hours, cooled and evaporated. The residue was triturated with acetone to give a yellow solid N-(2,1,3-benzothiadiazolyl)-piperazine, m.p. 240°-244° C., 365 mg (62%).
[0076] D. To a 125 ml round-bottomed flask equipped with condenser and nitrogen inlet were added 365 mg (1.13 mmol) N-(2,1,3-benzothiadiazolyl)-piperazine, 275 mg (1.13 mmol) 6-(2-bromoethyl)benzoxazolone, 359 mg (3.39 mmol) sodium carbonate, 2 mg sodium iodide and 40 ml ethanol. The reaction was heated at reflux for 2 days, cooled and evaporated. The residue was taken up in methylene chloride, washed with water, dried over sodium sulfate, and evaporated. The residue was chromatographed on silica gel using ethyl acetate/methanol as eluent and the product fractions collected, dissolved in methylene chloride/methanol, precipitated by addition of and ethereal solution of HCl, and the solid filtered, washed with ether, and dried to give 228 mg (45%), m.p. 166°-170° C.
EXAMPLE 14
[0077] 6-(2-(4-(1-Naphthyl)-piperazinyl)ethyl)benzothiazolone
[0078] To a 100 ml round-bottomed flask with condenser and nitrogen inlet were added 1.0 gram (3.88 mmol) of 6-(2-bromoethyl)benzothiazolone, 822 mg (3.88 mmol) N-(1-naphthyl)piperazine, 410 mg (3.88 mmol) sodium carbonate, and 50 ml methylisobutlyketone. The reaction was refluxed for 24 hours, cooled, and evaporated. The residue was taken up in ethyl acetate, washed with water and brine, dried over sodium sulfate, and evaporated. The resulting solid was treated with hot ethyl acetate to afford a white solid, m.p. 198°-220° C., 540 mg (36%).
EXAMPLE 15
[0079] 6-(2-(4-(3-benzoisothiazolyl)piperazinyl)ethyl)benzoxazolone
[0080] To a 125 ml round-bottomed flask equipped with condenser were added 4.82 grams (0.022 mol) of N-(3-benzoisothiazolyl)piperazine (prepared according to the procedure given in U.S. Pat. No. 4,411,901), 5.32 grams (0.022 mol) of 6-(2-bromo)ethylbenzoxazolone, 2.33 grams (0.022 mol) of sodium carbonate, and 50 ml of methyl isobutyl ketone. The mixture was refluxed for 18 hours. The reaction was cooled and partitioned between ethyl acetate and water. The ethyl acetate layer was isolated, washed with water and saturated aqueous sodium chloride solution dried over sodium sulfate, and evaporated to an oil. The oil was chromatographed on silica gel using ethyl acetate as eluent, and the product fractions collected and triturated with methylene chloride/isopropyl ether to give a white solid, 1 m.p. 185°-187° C. NMR (CDCl 3 ): 1.7 (bs, 1H), 2.8 (m, 8H), 3.6 (m, 4H), 6.9-8.0 (m, 7H).
EXAMPLE 16
[0081] 5-(2-(4-(1,2-benzisothiazol-3-yl)-piperazinyl)ethyl)oxindole
[0082] To a 125 ml round-bottom flask equipped with nitrogen inlet and condenser were added 0.62 grams (3.20 mmol) 5-(2-chloroethyl)-oxindole, 0.70 grams (3.20 mmol) sodium carbonate, 2 mg sodium iodide, and 30 ml methylisobutyl ketone. The reaction was refluxed 40 hours, cooled, filtered, and evaporated. The residue was chromatographed on silica gel, eluting the byproducts with ethyl acetate (1 1) and the product with 4% methanol in ethyl acetate (1.5 1). The product fractions (R f =0.2 in 5% methanol in ethyl acetate) were evaporated, taken up in methylene chloride, and precipitated by addition of ether saturated with HCl; the solid was filtered and washed with ether, dried, and washed with acetone. The latter was done by slurrying the solid acetone and filtering. The title compound was obtained as a high melting, non-hygroscopic solid product, m.p. 288°-288.5° C., 0.78 (59%).
[0083] In a manner analogous to that for preparing 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-oxindole, the following compounds were made:
5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-1-ethyloxindole hydrochloride, 25%, m.p. 278°-279° C.; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-1-methyloxindolehydrochloride hemihydrate, 42%, m.p. 283°-285° C.; MS(%): 392(1), 232(100), 177(31); Anal. for C 22 H 24 N 4 OS.HCl. 1/2 H 2 O: C, 60.33; H, 5.98; N, 12.79. Found: C, 60.37; H, 5.84; N, 12.77; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-1-(3-chlorophenyl)oxindole hydrochloride hydrate, 8%, m.p. 221°-223° C.; MS(%): 488(1), 256(4), 232(100), 177 (15); Anal. for C 27 H 25 ClN 4 OS.HCl.H 2 O: C, 59.67; H, 5.19; N, 10.31. Found: C 59.95, H 5.01, N 10.14; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-3,3-dimethyloxindole hydrochloride hemihydrate, 40%, m.p. 289°-291° C.; MS(%): 406(1), 232(100), 177(42); Anal. for C 23 H 26 N 4 OS.HCl. 1/2 H 2 O: C 61.11, H 6.24, 12.39. Found: C, 61.44; H, 6.22; N, 12.01; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-1,3-dimethyloxindole, 76%, m.p. 256° C.; 5′-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-spiro[cyclopentane-1,3′-indoline-]-2′-one hydrochloride hemihydrate, 50%, m.p. 291°-293° C. (dec.); MS(%): 432(1) 232(100), 200(11), 177(36); Anal. for C 25 H 28 N 4 OS.HCl 1/2 H 2 O: C, 62.81; H, 6.33; N, 11.72. Found: C 63.01, H. 6.32, N 11.34; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-1,3,3-trimethyloxindole hydrochloride hemihydrate, 63%, m.p. 225°-257° C.; MS(%): 420(1), 232(100), 177(37); Anal. for C 24 H 28 N 4 OS.HCl. 1/2 H 2 O: C, 61.85; H, 6.49; N, 12.02. Found: C, 61.97; H, 6.34; N, 11.93; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ether)-6-fluorooxindole hydrochloride hydrate, 18%, m.p. 291°-293° C.; MS(%): 396(1), 232(100), 177(53); Anal. for C 2 , H 2 , H 4 FOS.HCl. 1/2 H 2 O: C, 55.93; H, 5.36; N, 12.42. Found: C, 56.39; H, 5.30; N, 12.19; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-7-fluorooxindole hydrochloride, 9%, m.p. 2530 C.; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-6-chlorooxindole hydrochloride, 20%, m.p.>300° C.; MS(%): 488(1), 256(4), 232(100), 177(15); Analysis for C 2 , H 21 ClN 4 OS.HCl. 1/2 H 2 O: C, 52.50; H, 4.71; N, 11.39. Found: C, 52.83; H, 4.93; N, 11.42; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)ethyl)-6-fluoro-3,3-dimethyloxindole hydrochloride, 35%, m.p. 284°-2860 C.; Anal. for C 23 H 25 FN 4 OS.HCl.H 2 O: C 57.67, H 5.89, N 11.70. Found: C, 58.03; H, 5.79; N, 11.77; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)butyl)oxindole hemihydrate, 26%, m.p. 131°-1350 C.; MS(%): 406(2), 270(8), 243(65), 232(23), 177(45), 163(100); Anal. for C 23 H 26 N 4 OS. 1/2 H 2 O: C, 66.48; H, 6.55; N, 13.48. Found: C, 66.83; H, 6.30; N, 13.08; 5-(2-(4-(1,2-benzisothiazol-3-yl)piperazinyl)butyl)-7-fluorooxindole hydrate, 7%, m.p. 126°-129° C.; MS(%): 424(3); Anal. for C 23 H 25 FN 4 OS.H 2 O: C, 57.67; H, 5.89; N, 11.70. Found: C, 57.96; H, 5.62; N, 11.47; 5-(2-(4-(1,2-benzisothiazol-3yl)piperazinyl)butyl)-1-ethyloxindole hemihydrate, 25%, m.p. 1260-1280 C.; MS(%): 434(2), 298(10), 271(55), 232(34), 177(53), 163(100); Anal. for C 25 H 30 N 4 OS. 1/2 H 2 O: C, 67.69; H, 7.04; N, 12.63. Found: C, 67.94; H, 6.73; N, 12.21; 5-(2-(4-(naphthalen-1-yl)piperazinyl)ethyl)-1-ethyloxindole hydrochloride hydrate, 21%, m.p.>300° C.; MS(%): 399(1), 225(96), 182(30), 70(100); Anal. for C 26 H 29 N 3 O.HCl.H 2 O: C, 68.78; H, 7.10; N, 9.26. Found: C, 69.09; H, 6.72; N, 9.20; 5-(2-(4-(naphthalen-1-yl)piperazinyl)ethyl)-6-fluorooxindole hydrochloride, 23%, m.p. 2890-2910 C.; MS(%): 389(1), 232(3), 225(100), 182(32), 70(84); Anal. for C 24 H 24 FN 3 O.HCl. 1/2 CH 2 Cl 2 ; C, 62.82; H, 5.60; N, 8.97. Found: C, 62.42; H, 5.82; N, 8.77; 5-(2-(4-(naphthalen-1yl)piperazinyl)ethyl)-7-fluorooxindole hydrochloride, 22%, m.p. 308° C.(dec.); MS(%): 389(1), 225(100); Anal. for C 24 H 24 FN 3 O.HCl.CH 2 Cl 2 ; C 58.78, H 5.93, N 8.23. Found: C, 58.82; H, 5.80; N, 8.27;
EXAMPLE 17
[0100] 6-(4-(2-(3-Benzisothiazolyl)piperazinyl)ethyl)phenyl)benzothiazolone
[0101] To a 100 ml round-bottomed flask equipped with condenser and nitrogen in let were added 1.03 grams (4 mmol) 6-(2-bromoethyl)-benzothiazolone, 0.88 grams (4 mmol) N-benzisothiazolylpiperazine, 0.84 grams (8 mmol) sodium carbonate, 2 mg sodium iodide, and 40 ml methylisobutyl ketone. The reaction was refluxed 36 hours, cooled, filtered, and the filtrate evaporated. The residue was chromatographed on silica gel using ethyl acetate as eluent to afford an oil, which was taken up in methylene chloride and precipitated by addition of ether saturated with HCl. The solid was filtered, washed with ether, dried briefly, washed with a minimal amount of acetone and dried to afford a white solid, m.p. 288°-290° C., 1.44 grams (76.7%).
EXAMPLE A
[0102] A. Following the general procedure for the preparation of 5-(chloroacetyl)oxindole in Example 12A, the following intermediates were prepared from the appropriate oxindoles:
5-(chloroacetyl)-1-ethyl-oxindole (81%, m.p. 1570-1590 C., NMR(CDCl 3 ); 1.30(t,3H), 3.60(s,2H), 3.85(q,2H), 4.70(s,2H), 6.85-8.15(m,2H); 5-(chloroacetyl)-1-methyloxindole(C 1 , H 10 ClNO 2 , 92%, m.p. 2010-2020 C.; 1(3-chlorophenyl)-5(chloroacetyl)oxindole, 98% m.p. 143°-145° C., NMR(DMSO-d 6 ): 3.85(br s,2H), 5.10(s,2H), 6.8(d,1H), 7.4-7.6(m,4H), 7.9 (s+d,2H); MS(%): 319(17, 270(100), 179(46), 178(38); 1,3-dimethyl-5-(chloroacetyl)oxindole, 97% m.p. 206°-207° 5-(chloroacetyl)-spirocyclopentane[1,3′]-indolone, 99%, m.p. 203°-204° C.(dec).; NMR(DMSO-d 6 ): 2.0(brs,8H), 4.95(s,2H), 6.9(d,1H), 7.8(d+s,2H), 10.6(brs, 1H); 5-(chloroacetyl)-1,3,3-trimethyloxindole, 82%, m.p. 1820-185° C., NMR(CDCl 3 ): 1.45(s,6H), 3.25(s,3H), 4.65(s,2H), 6.9(d, 1H), 7.9(s,1H), 8.0(d,1H); 6-fluoro-5-(chloroacetyl)oxindole, 96%, m.p. 1780-1800 C.; NMR(DMSO-d 6 ): 3.5(s,2H), 4.8(d,2H), 6.7-7.2(m,2H), 7.8(d,1H); 7-fluoro5-(chloroacetyl)oxindole, 91%, m.p. 1940-1960 C., NMR(DMSO-d 6 ): 3.68(s,2H), 5.13(s,2H) 7.65-7.9(dd,2H); 6-chloro-5-(chloroacetyl)oxindole, 99%, m.p. 206°-207° C.; 5-(chloroacetyl)-3,3-dimethyl-6-fluorooxindole, 89%, m.p. 185°-1880 C.; 5-(y-chlorobutyryl)oxindole, 84%, oil, MS(%): 239, 237(55); 1-ethyl-5-(y-chlorobutyryl)oxindole, 99%, oil, NMR(CDCl 3 ): 1.2(t,3H), 1.5-2.7(m,5H), 3.0-3.2(m,2H), 3.5-4.0(m,3H), 6.8-7.0(d,1H), 7.9(s,1H), 7.95(d,1H), and 5-(y-chlorobutyryl)-7-fluorooxindole, 53%, m.p. 156°-160° C.
EXAMPLE B
[0116] By the same procedure as that used to prepare 5-(2-chlorethyl)oxindole in Example 12B, the following were prepared:
5-(2-chloroethyl)-1-ethyloxindole, 93%, m.p. 120°-122° C.; NMR (CDCl 3 ): 1.30(t,2H), 3.55(s,2H), 3.65-4.0(m,4H), 6.8-7.3(m,3H); 5-(2-chloroethyl)-1-methyloxindole, 99%, m.p. 127°-130° C.; NMR (CDCl 3 ): 3.1(t,2H), 3.2(s,2H), 3.5(s,2H), 3.75(t,2H), 6.8(d,1H), 7.15(s,1H), 7.3(d,1H); 5-(2-chloroethyl)-1-(3-chlorophenyl)oxindole, 83%, m.p. 75°-76° C.; 5-(2-chloroethyl)-1,3-dimethyloxindole, 58%, m.p. 73°-750 C., NMR CDCl 3 ): 1.45-1.55(d,3H), 3.03-3.2(t,2H), 3.25(s,3H), 3.30-3.60(q,1H), 3.65-3.90(t,2H), 6.85-6.90(d,1H), 7.15(s,1H), 7.15-7.30(d,1H); 5′-(2-chloroethyl)-spiro[cyclopentane-1,3′-indoline]-2′-one, 92%, m.p. 140°-142° C.; NMR(DMSO-d 6 ): 2.8(brs,8H), 2.90(t,2H), 3.7(t,2H), 6.6-7.1(m,3H), 10.2(brs,1H); 5-(2-chloroethyl)-,3,3-trimethyloxindole, 83%, oil; 5-(2-chloroethyl)-6-fluorooxindole 62%, m.p. 1880-190° C.; NMR(DMSO-ds) 3.05(t,2H), 3.5(2,2H), 3.85(t,2H), 6.6-7.3(m,2H); 5-(2-chloroethyl)-7-fluorooxindole, 79%, m.p. 176°-1790 C.; MS(%); 213(50), 180(20), 164(100), 136(76); 5-(2-chloroethyl)-6-chlorooxindole, 94%, m.p. 210°-211° C.; 5-(2-chloroethyl)-3,3-dimethyl-6-fluorooxindole (C 12 H 13 ClFNO, 84%, m.p. 195°-1960 C., NMR(DMSO-d 6 ): 1.3(s,6H), 3.05(t,2H), 3.7(t,2H), 6.65(d,1H), 7.1(d,1H), 10.1(br s,1H); 5-(4-chlorobutyl)oxindole, 40%, oil, NMR(CDCl 3 ): 1.6-2.0(m,4H), 2.6(m,2H), 3.6(m,4H), 6.8-7.15(m,3H), 9.05(br s, 1H); 5-(4-chlorobutyl)-ethyloxindole, 48%, oil, NMR(CDCl 3 ): 1.25(t,3H), 1.5-1.95(m,4H), 2.6(m,2H), 3.5(s,2H), 3.55(t,2H), 3.75(q,2H), 6.7-7.2(m,3H); and
[0129] 5-(4-chlorobutyl)-7-fluorooxindole, 71%, m.p. 1680-173° C.
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The present invention relates to a method for treatments relating to bipolar disorder in a mammal, including a human, the treatments including treatment of rapid-cycling bipolar disorder, treatment of symptoms of bipolar disorder selected from the group consisting of acute mania and depression, treatment for effecting mood stabilization; treatment for preventing relapse into bipolar episodes, and for the treatment of suicidal thoughts and tendencies associated with bipolar disorder, comprising administering to said mammal an effective amount of a compound of the formula I:
or a pharmaceutically acceptable acid addition salt thereof, wherein Ar, n, X, and Y are as defined.
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PRIOR RELATED APPLICATION DATA
This application is a continuation of U.S. application Ser. No. 12/463,848, filed May 11, 2009, which claims priority to Indian Patent Application No. 1157/CHE/2008, filed May 12, 2008, the entire content of which is incorporated herein by reference in its entirety.
BACKGROUND OF INVENTION
1. Field of Invention
This invention relates to reactors such as rotary kilns for the gasification of mixed size of solid carbonaceous materials such as biomass and solid wastes in a tumbling state and particularly to the gas distribution port for introducing gases such as air, oxygen, and steam to the interior of the rotary kiln wherein this gas distributor assures gas solid mixing inside the reactor to promote gas solid reaction.
2. General Background and the State of the Art
In the last two decades or so, interest in biomass gasification has picked up as means of producing energy from renewable resources to supplement the foreign imports as well as to develop strategy for distributed generation for reasons of meeting energy security needs. This renewed interest has encouraged development of new and improved methods for making biomass gasification efficient and fuel gas generated from these cleaner in terms of its tar content. Biomass typically comprises collectable, plant-derived materials that may be readily abundant and relevantly inexpensive in comparison to fossil fuels. Additionally, biomass may be potentially convertible to feedstock chemicals or used for electricity generation. Some examples of sources of biomass may be, without limitation, wood, grass, agriculture and farm wastes, manure, waste paper, rice straw or rice husks, corn stores, corn cobs, sorghum stover, poultry litter, sugarcane bagasse, waste resulting from vegetable oil extraction, peanut shells, coconut shells, shredded bark, food waste, urban refuse and municipal solid waste.
The present invention is directed to a reactor vessel in which solid, liquid and gaseous organic wastes such as but not necessarily limited to forestry and agricultural residues, animal wastes, bacterial sludge, sewage sludge, municipal solid waste, food wastes, animal bovine parts, fungal material, industrial solid waste, waste tires, coal washing residue, petroleum coke, oil shale, even coal, peat and lignite, waste oil, industrial liquid wastes, residuals from petroleum refining and volatile organic compounds generated by the industrial processes are transformed into gaseous fuels with maximum conversion efficiency while maintaining resultant synthesis fuel gas free of tar and oil. The organic materials of this type commonly referred to as carbonaceous materials include fixed carbon, volatile matter and ash.
Moisture present with all of the carbonaceous is also included in the volatile matter. The primary objective of the transformation is to obtain essentially complete conversion of carbon and volatile matter into synthesis fuel gas, while leaving only ash as solid residue. This transformation of the organic material takes place by combining these organic materials with steam and air or oxygen in a high temperature environment. Gas-solid contact, the temperature and the time allocated for gas-solid contact at a given temperature all play a role in the extent of conversion of the organic material introduced into the reactor vessel. Most of the time, the moisture content of the organic feed material is adequate for the transformation reactions. However, the present invention also includes the benefits of introducing additional moisture to produce uniform quality of the synthesis gas from this apparatus. The present invention does not preclude pre-drying of the organic feed material prior to its introduction into the reactor vessel.
The advantages of converting organic material into synthesis fuel gas over directly combusting the carbonaceous material are quite significant. Direct combustion of carbonaceous materials mentioned above usually results in smoke and discharge of unwarranted polluting compounds to the detriment of human health. Besides, direct combustion results in deposition of tar in the chimneys which poses a fire hazard. In contrast, the synthesis fuel gas, after production and clean-up, contains simple clean burning combustible gases, namely carbon monoxide, hydrogen and some methane along with non-combustible nitrogen, carbon dioxide and water vapor. This synthesis fuel gas is also suitable for fuel use for internal combustion engines.
The ideal device for the transformation of carbonaceous material into synthesis fuel gas would comprise of ability to introduce all types of carbonaceous materials without limitations in reason of its origin, size, and composition and that would also provide ideal mixing between solids present in the device and gas including air and steam that is introduced into the apparatus. There are number of devices that are capable of transforming all sorts of carbonaceous materials into synthetic fuel gas; however, none of them are without limitations.
For example, the bubbling fluidized bed reactors are well known for providing ideal contact between solids and gases; however, these devices lack versatility with respect to handling multiple types and sizes of carbonaceous materials. The operation of fluidized bed device is generally restricted to one particular type and one size of carbonaceous material since any variation in these would upset the delicate balance between fluidization velocity and the size of the carbonaceous material as well as the balance between the composition of the carbonaceous material and amount of reaction gases such as air and steam introduced into the reactor.
Another example of reactor with good contact between solid and gas is the circulating entrained bed reactor. This type of reactor increases contact time between the solids and gases by continuous recirculation of the solids inside the reactor vessel. Again this type of reactor lacks versatility with respect to type and size of the carbonaceous material.
In the small-scale category of the available reactors, common ones are updraft gasifiers, downdraft gasifiers, and cross-draft gasifiers. All of these types of reactors have restrictions with respect to the density and the size of the carbonaceous material they can handle. Besides none of these reactors have ability to provide ideal mixing between solids and gases which is a prerequisite for obtaining maximum conversion of carbonaceous material into synthesis fuel gas. As a result of poor mixing, these reactors lose significant amount of carbon with the solid residue.
In comparison to all of the aforementioned devices, the rotary reactor such as kiln is most flexible and versatile in terms of handling vast array of carbonaceous material irrespective, within reasons, of type, composition, and size. The rotary kiln device is also suitable for operating at full load and part load as necessitated by synthesis fuel gas demand or by availability of the carbonaceous material. The primary weakness of the rotary kiln is gas solid mixing without which it is difficult to attain high conversion of carbonaceous fuel into synthesis fuel gas. In a study performed by CPL Industries (Reference 1 ), it was quite apparent that without allowing provisions for suitable mixing inside the kiln it was not possible to attain high transformations of carbonaceous fuel into synthesis fuel gas. Without adequate mixing between solids and gases, the air and steam has tendency to bypass reaction with solids and instead prefers to react with gases thereby impairing the quality of synthesis fuel gas with respect to its heating value. Moreover the bypassing of air and steam results in lower conversion of carbonaceous material and hence lot of carbon is lost with the solid residue.
The present invention provides an apparatus to systematically introduce air, steam, and other gases according to the dictates of the gasification reactions which when installed inside of the rotating reactor such as kiln tremendously improves gas solid mixing inside the reactor and thereby assures maximum conversion of carbonaceous material into synthesis fuel gas. With this ability for gas solid mixing and its inherent flexibility with respect to accepting wide array of carbonaceous material irrespective of type, composition, and size; and combined with its ability to operate within large variation of loading of the carbonaceous material, the kiln reactor would become the reactor of choice for distributed power generation for smaller and larger applications.
Some prior attempts to provide improved gas solid mixing in a rotary kiln as well as attempts to improve conversion of carbonaceous material into synthesis fuel gas in rotary kiln by indirect means are mentioned below.
DESCRIPTION OF PRIOR ART
In the prior art, rotary kilns are known where the air, steam, and fuel are admitted into the reactor over its entire length by providing plurality of ports through the shell of the kiln. Examples of these arrangements are disclosed in the U.S. Pat. Nos. 1,216,667, 2,091,850 and 3,182,980. The port arrangements for such kilns are disclosed in U.S. Pat. Nos. 3,794,483; 3,946,949; and 4,214,707. In certain of the prior art, e.g., U.S. Pat. No. 2,091,850, the air is injected into the kiln through hundreds of ports drilled into the shell of the kiln. Even though this art provides means of introducing air into the kiln either below the material charge of the bed or when the ports are above the bed, its operation, control, and maintenance is cumbersome. If aforesaid apparatus is operated to process mixed size materials containing particles having smaller diameter than the port, these smaller particles may enter the ports and the associated piping causing the clogging of the ports and thereby restricting the flow of air into the reactor. When the blockage occur in several of these ports, the amount of air that can be introduced into the reactor decreases correspondingly and therefore the capacity of the kiln is also reduced correspondingly. This sort of impairment also increases the necessity of maintenance and hence increases the downtime of the reactor.
In U.S. Pat. No. 4,214,707 improvement in port design to prevent material from entering port and associated piping has been disclosed by making these ports self purging. In this art, each port has a nozzle having a plurality of orifices for introducing air into the kiln. Behind the nozzle is a labyrinth trap. Particulates from the kiln are allowed to pass through the nozzle orifices into the trap as the port passes beneath the material in the kiln. A plurality of orifices in the trap causes air to swirl as the air passes through the trap and carry them into the kiln. While this improvement act to prevent particulate material from entering the associated port pipe, some of the very smallest particulate material will eventually elude this screening mechanism and pass into the piping and eventually cause a restriction for the air flow into the reactor.
Further improvements for the port design which are confined entirely on the shell of the kiln are enumerated in U.S. Pat. Nos. 4,373,908 and 4,373,909 in which design to prevent nozzle blockage is taught. This method, however is complex and tedious.
Because of difficulties associated with introducing air and steam uniformly into a rotating reactor to communicate effectively with the solids residing in the kiln, many investigators have resorted to completely avoiding introduction of these gases into the reactor and instead have resorted to convert biomass and other carbonaceous materials into fuel gas by indirect heating of the shell of the kiln. In one of the studies conducted by Androutsopoulos and Hatzilyberis (Reference 2 ), the investigators operated the rotary kiln reactor for the gasification of lignite coal under allothermal conditions in which heat was supplied to the reactor by indirect heating of the kiln shell. The composition of the gas was found to be comparable to that produced by the gasification reactors with intense gas solid mixing. The investigators stated the advantage of kiln reactor as being able to process wide range of particle size without need for screening as is generally the case with other type of reactors such as fluidized bed and entrained bed reactors. This study did not mention the extent of the conversion of the lignite coal in the absence of the direct injection of the air into the reactor; however judging from another study with and without air injection into the kiln reactor (Reference 1 ), the conversion of coal attained would be suspected to be at the lower end.
Another similar study by Fantozzi, D'Alessandro, and Desideri (Reference 3), the investigators again relied on indirect heating of the kiln shell to generate fuel gas from the biomass. In this study it is implied that significant amount of carbon is left in the solid residue and unless used as fuel for indirect heating of the kiln shell, the process efficiency for converting biomass into fuel gas is greatly diminished.
In the U.S. Patent Application Number 20050095183, a method for introducing air and steam into the kiln is disclosed. In this method, stationary pipe divided into several segments with plurality of ports is fixed inside of the kiln and which is supported by the stationary ends of the kiln. Various configurations of the ports are disclosed to introduce air and steam into the reactor. This port is however based on uniform disbursement of air and steam from around each section of the port which may result largely in undesirable gas to gas reaction rather than intended gas to solid reaction. The gas solid mixing is greatly dependent upon the positioning of the stationary pipe and the size and the location of the ports with respect to the solids residing in the kiln. This particular distributor has limited ability to cause intense mixing between the gas and solids in the reactor which is a prerequisite for causing optimum conversion of solid biomass and other solid carbonaceous fuels into gaseous fuel. The present invention is an improvement on this particular aspect of gas solid mixing inside the kiln reactor.
SUMMARY OF THE INVENTION
According to a preferred embodiment of the present invention, there is provided a port assembly secured by the stationary plate of the rotary kiln and positioned for communication with the interior of the rotary kiln to deliver independently controlled flow of reactant gases to predetermined sections of the rotary kiln and such that the reactant gases are in intimate contact with the solids present inside the rotary kiln. The port assembly comprises of a main conduit extending from front to the rear of the rotary kiln. The conduit is divided into four or more sections for introducing gases such as air, oxygen and steam into the kiln at the locations inside the kiln coinciding with the specific sections of the conduit. Each section of the conduit communicates independently to the supply of reactant gases for that particular section. The amount of gas and the composition of gas supplied to each of the section is independently controlled to commensurate with the specific gas solid reaction requirement at a particular stage of reaction along the rotary kiln. The conduit is placed along the vertical axis of the rotary kiln and positioned such that the lower portion of the conduit is immersed in the layer of solids present at the bottom of the rotating kiln. Each section of the port assembly communicates with the kiln through the plurality of the nozzles drilled into each section of the port. The nozzles are confined to lower third circumference of the conduit to prevent escape of reactant gases into the main gas stream without having first contacted with the solids present in the rotary kiln. The immersion of the lower section of the conduit into the layer of solids residing on the bottom of the kiln promotes intimate mixing between the gas and solids and thereby accords first opportunity for reactant gases to react with solids prior to merging into main gas stream in the rotary kiln.
For a typical gasification of carbonaceous material such as biomass with air or oxygen and steam, there are at least four stages of reactions that take place along the rotary kiln. In the first stage of reaction, as soon as the biomass is introduced into the rotary kiln gasifier, the biomass gravitates towards the bottom of the kiln and comes into contact with hot refractory lining which is holding the heat. The heat is transferred from the refractory to the biomass and as a result the temperature of the biomass rises which in turn causes the moisture in the biomass to evaporate. The reactant gases introduced in this zone merely helps to carry the devolatilized moisture into the main gas stream of the kiln. In the first zone depending upon the size of the zone, capacity of the kiln in terms of the feed rate of the carbonaceous material into the kiln, the temperature of the refractory, and the heat capacity of the refractory, the temperature of the biomass may attain temperature as high as 500 deg F. This zone of the rotary kiln gasifier is termed as drying section.
In the second stage, the temperature of the biomass continues to rise as the heat continues to transfer from the refractory to the biomass. As the temperature of the biomass continues to rise, the volatile organics begin to be released from the biomass. This zone of the rotary kiln gasifier is termed as devolatalization zone. The temperature in this zone typically rises to more than 1000 deg F. which corresponds to flash point of many of the organic compounds which are being released from the biomass. The reactant gases introduced in this zone, especially the oxygen-bearing gases such as air will begin reacting with these organic compounds to break them into simpler compounds. The steam present in the reactant gases would do the likewise destruction of the heavier organic compounds to yield simpler compounds.
Once the biomass and the attendant organic compounds have attained the ignition temperature in the third zone of the reactions, the air and/or oxygen present in the reactant gases begin to partially combust the volatile organic compounds emanating from the biomass in contact with the hot refractory and also combusts portion of carbon present in the devolatalized biomass. This combustion is necessary to carry out the reactions between gases and solids and also to maintain temperature in the reactor that would sustain endothermic reactions between steam and the carbonaceous materials to yield synthesis fuel gas. The temperature in this zone could rise way beyond 2000 deg F. but it is generally controlled to less than 2200 deg F. by limiting the amount of oxidant introduced in this zone. The temperature control is also necessary to maintain the integrity of the refractory. The combustion reaction also replenishes the heat to the refractory lining so that process can be carried out in a continuous manner. The combination of high temperature and availability of heat released from partial combustion also allow the endothermic reaction between the carbon present in the devolatalized biomass and steam present in the reactant gases to take place in this zone. The partial combustion reactions produces mixture of carbon monoxide and carbon dioxide and the reactions between steam and carbon produces the mixture of hydrogen, carbon monoxide, and carbon dioxide. In this zone, since the temperature is high, some of the steam will also react with organic compounds formed in the second zone and break those organic compounds to methane, hydrogen, carbon monoxide, and carbon dioxide. This zone of partial combustion and gasification is termed as combustion/gasification section. Ideally, major fraction of the reactant gases is introduced in this section.
In the fourth zone of the reaction, termed as gasification section, the reactant gases comprise primarily of steam. The use of oxidant is generally avoided since oxygen in this zone may preferentially tend to react with fuel gases produced in the earlier sections and thereby depleting its calorific value. In contrast, because of the reaction conditions at high temperature are more conducive for carbon steam reactions, it is preferred that steam is allowed to react with last bit of carbon present in the devolatalized and partially combusted biomass to produce more hydrogen and carbon monoxide. This zone also provides additional residence time for remaining heavy volatile compounds to break down into smaller and simpler compounds by reactions with steam.
Overall the gasification reactions consume less than fifty percent of stoichiometric oxygen required for complete combustion of the carbonaceous material. The quantity of gas produced in the kiln is significantly smaller than that produced during total combustion of the carbonaceous materials. Therefore the gasification equipment is much smaller than the combustor. It is also much easier and economical to clean the small quantity of gas. After cleaning the gas for the removal of chlorine and sulfur compounds formed during gas solid reactions taking place at various stages inside the rotary kiln gasifier, the fuel gas comprising of carbon monoxide, hydrogen, carbon dioxide, residual nitrogen, residual steam, and smaller hydrocarbon compounds such as methane and ethane is the final product available for use as clean fuel for boilers or for gas engines.
Thus it is apparent from the above description that the size of each section of the port assembly and the amount and the type of reactant gases introduced into the rotary kiln gasifier through each of these section largely depends upon the properties of the carbonaceous material being processed in the rotary kiln gasifier and can be adjusted accordingly. Any and all of these alterations are implied and included in this invention.
For best results it is necessary to employ conduit of adequate size that will enable adequate flow of the reactant gases to the appropriate reaction section within the rotary kiln. It is also necessary to employ adequate size of conduit that communicates each section of the gas port to the supply of the reactant gases. It is also necessary to provide adequate number and adequate size of the nozzles within each section of the port to deliver adequate reaction gases to the appropriate reaction section within the rotary kiln without compromising the available pressure drop for the reactant gas supply. In order to assure intended gas supply from a particular section of the port, the area of the nozzles provided in that particular section should at least be equal to the area of the conduit that communicates that particular section of the port to the reactant gas supply.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of general arrangement of the gas distribution port for a rotating kiln gasifier.
FIG. 2 is a depiction of reactions taking place within the rotary kiln gasifier.
FIG. 3 is a bottom view of the interior portion of the gas distribution port.
FIG. 4 is a cross section of the kiln gasifier with gas distribution port.
FIG. 5 is an expanded cross section view of the port assembly section in the interior of the rotary kiln.
FIG. 6 is a depiction of temperature profile inside the rotary kiln gasifier.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts one of many types of rotary kiln apparatus with which the present invention can be practiced. Referring to FIG. 1 , the rotary kiln gasifier 1 is a hollow refractory lined vessel with suitable inlets for feeding carbonaceous material 2 , suitable inlet for feeding reactant gases such as air and steam 3 , suitable outlet for fuel gas 4 , and suitable outlet for ash 5 . The rotary kiln depicted in FIG. 1 can also operate as combustor with equal effectiveness. The gasifier 1 should be large enough to gasify desired capacity of carbonaceous material and to provide adequate residence time for the gasification reactions between carbonaceous materials and the gaseous reactants. The interior of the gasifier 1 is preferably refractory lined 6 or alternatively surrounded by heat transfer devices such as tubes containing flowing liquids to absorb heat. The refractory lined kiln is preferred because the hot refractory retains heat and transfers that heat to the carbonaceous material coming in its contact thereby raising the temperature of the said carbonaceous material and thereby making it easier for gaseous reactant to initiate gasification reactions with the said solids.
Because of the nature of the rotating kiln, when the carbonaceous solid material is introduced into the said kiln, the solid carbonaceous material generally gravitates towards the walls and ultimately to the bottom of the said kiln. In contrast the flow of gas introduced at the head of the kiln flows through the middle of the kiln and as a result minimal interaction between the solids and gas is expected in this type of devices. In order to get maximum benefit out of this type of devices it is essential to maximize gas-solid interaction. This is exactly what the rotating gas distributor 7 of the present invention achieves.
The gas distributor 3 is essentially a gas port as a means of introducing and distributing reactant gases such as gaseous fuel, air, oxygen, and steam into the rotary kiln for processing of any solids to attain maximum interaction between the solid materials present in the kiln with the reactant gases that are being introduced through the said gas distributor. The example here depicts one application of the invention for the gasification of biomass which requires four stages of reaction for converting it into gaseous fuel gas. The invention is described for this specific application without departing from the main spirit of the invention so that the embodiments of the invention are properly understood.
The gas port 3 is supported at both ends of the kiln by the front and rear hoods of the kiln with sealed insertions 7 and 8 respectively and comprises of a conduit which is divided into four noncommunicating sections 9 , 10 , 11 , and 12 . Each of the section 9 , 10 , 11 , and 12 communicates with the gas supply via other conduits 13 , 14 , 15 , and 16 . The supplies of gas to each of these conduits are independently controlled by control valves 17 , 18 , 19 , and 20 . The quantity and the composition of the reactant gases vary according to the dictates of the solids processing. For gasification of biomass exemplified here, the reactant gases comprises primarily of air, oxygen, and steam. The length of each of the four noncommunicating sections 9 , 10 , 11 , and 12 are dependent upon type of material being processed. Similarly, the diameters of the conduits 13 , 14 , 15 , and 16 also depend upon the material being processed and the processing capacity of the rotary kiln gasifier.
The four stages of reactions required for complete gasification of the biomass include drying to remove moisture from the biomass; devolatalization of organic compounds from the biomass; partial combustion of biomass to provide heat required for sustaining reactions necessary for drying, devolatalization, and gasification; and finally the gasification of residual biomass after the moisture and volatile organic compounds are removed from the biomass. FIG. 2 depicts the sections of rotary kiln where these reactions occur. Following is brief description of reactions occurring in these four sections of the rotary kiln and which are supported by reactant gases supplied independently to each of the sections 9 , 10 , 11 , and 12 of the gas distribution port.
In the first stage of reaction, as soon as the biomass is introduced into the rotary kiln gasifier, the biomass gravitates towards the bottom of the kiln and comes into contact with hot refractory lining 6 which is holding the heat. The heat is transferred from the refractory to the biomass and as a result the temperature of the biomass rises which in turn causes the moisture in the biomass to evaporate. The reactant gases introduced in this zone merely helps to carry the devolatilized moisture into the main gas stream of the kiln. In the first zone depending upon the size of the zone 9 , capacity of the kiln in terms of the feed rate of the carbonaceous material into the kiln through inlet 2 , the temperature of the refractory 6 , and the heat capacity of the refractory 6 , the temperature of the biomass may attain temperature as high as 500 deg F. This zone of the rotary kiln gasifier 1 is termed as drying section 9 as shown in FIG. 2 .
The primary reaction in this drying section of the rotary kiln 1 is evolution of the moisture from the biomass represented as:
Wet Biomass+Heat.fwdarw.Dry Biomass+Steam
In the second stage of the gasification reactions, termed as devolatalization section 10 , the temperature of the biomass continues to rise as the heat continues to transfer from the refractory 6 to the biomass. As the temperature of the biomass continues to rise, the volatile organics begin to be released from the biomass. The temperature in this zone typically rises to more than 1000 deg F. which corresponds to flash point of many of the organic compounds which are being released from the biomass. The reactant gases introduced in this zone, especially the oxygen-bearing gases such as air will begin reacting with these organic compounds to break them into simpler compounds. The steam present in the reactant gases would do the likewise destruction of the heavier organic compounds to yield simpler compounds.
The gasification reactions occurring in devolatalization section of the rotary kiln 1 are represented as:
Pyrolysis
Biomass+Heat.fwdarw.CH 4 +CO+CO 2 +H 2 O+H 2 +Alcohols+Oils+Tars+C
Gasification
CnHmOp+xO 2 +(2n−2x−p)H2O+Heat.frwdarw.(n−y)CO2+(2n−2x−p+m/2−y)H2+yCO—+yH2O
Where x the oxygen-to-fuel molar ratio and y is the number of moles of CO2 that reacts with H2 to produce CO and H2O due to the water gas shift reaction. This reaction is exothermic at low values of x, and exothermic at high values of .xi. At an intermediate value (x0), the heat of reaction is zero, and is called auto-thermal reforming.
In the third stage of gasification depicted in FIG. 2 as Combustion/Gasification section corresponding to the third section 11 of the gas distribution port 3 some of the crucial reactions occur. Because of continued exposure to heat from the refractory lining 6 and because of partial combustion of evolved organic compounds in devolatalization, the biomass is sufficiently heated up to reach ignition temperature with incoming reactant gases especially with oxygen bearing gases. Once the biomass and the attendant organic compounds have attained this ignition temperature in the third zone of the reactions, the air and/or oxygen present in the reactant gases begin to partially combust the volatile organic compounds emanating from the biomass in contact with the hot refractory 6 and also begins to combust portion of carbon present in the devolatalized biomass. This combustion is necessary to carry out the reactions between gases and solids and also to maintain temperature in the rotary kiln reactor 1 that would sustain endothermic reactions between steam and the carbonaceous materials to yield synthesis fuel gas. The temperature in this zone could rise way beyond 2000 deg F. but it is generally controlled to less than 2200 deg F. by limiting the amount of oxidant introduced in this zone. The temperature control is also necessary to maintain the integrity of the refractory 6 . The combustion reaction also replenishes the heat to the refractory lining so that process can be carried out in a continuous manner. The combination of high temperature and availability of heat released from partial combustion also allow the endothermic reaction between the carbon present in the devolatalized biomass and steam present in the reactant gases to take place in this zone. The partial combustion reactions produces mixture of carbon monoxide and carbon dioxide and the reactions between steam and carbon produces the mixture of hydrogen, carbon monoxide, and carbon dioxide. In this zone, since the temperature is high, some of the steam will also react with organic compounds formed in the second zone and break those organic compounds to methane, hydrogen, carbon monoxide, and carbon dioxide. This zone of partial combustion and gasification is termed as combustion/gasification section. Ideally, major fraction of the reactant gases is introduced in this section 11 of the gas distribution apparatus.
The following reactions take place in this combustion/gasification section of the rotary kiln:
Pyrolysis
Biomass+Heat.fwdarw.CH 4 +CO+CO 2 +H 2 O+H 2 +Alcohols+Oils+Tars+C
Gasification
C nHmOp+xO 2 +(2n−2x−p)H2O+Heat.fwdarw.(n−y)CO2+(2n−2x−p+m/2−y)H2+yCO—+yH2O
Where x the oxygen-to-fuel molar ratio and y is the number of moles of CO2 that reacts with H2 to produce CO and H2O due to the water gas shift reaction. This reaction is exothermic at low values of x, and exothermic at high values of .xi. At an intermediate value (x0), the heat of reaction is zero, and is called auto-thermal reforming.
Char Combustion
C+O2.fwdarw.CO2+Heat
Carbon Steam Reaction
C+H 2O+Heat.fwdarw.CO+H2
Hydrogen Combustion
H2+½O2.fwdarw.H2O+Heat
Reverse Boudard Reaction
C+CO2+Heat.fwdarw.2CO
Water-Gas Shift
CO+H2O.fwdarw.CO2+H2+Heat
In the fourth zone of the reaction reactions, termed as gasification section corresponding to fourth section 12 of the gas distribution assembly 3 , the reactant gases comprise primarily of steam. The use of oxidant is generally avoided since oxygen in this zone may preferentially tend to react with fuel gases produced in the earlier sections and thereby depleting its calorific value. In contrast, because of the reaction conditions at high temperature are more conducive for carbon steam reactions, it is preferred that steam is allowed to react with last bit of carbon present in the devolatalized and partially combusted biomass to produce more hydrogen and carbon monoxide. This zone also provides additional residence time for remaining heavy volatile compounds to break down into smaller and simpler compounds by reactions with steam. Because of promoting endothermic reaction in gasification zone, and because the heat of reaction is derived from the bulk of the gases leaving the combustion/gasification section of the rotary kiln gasifier 1 , the bulk temperature of gases in this zone drops by 200 to 300 deg F. The drop in gas temperature is largely dependent upon amount of residual carbon as well as on the amount of steam introduced in the fourth section 12 of the gas distribution assembly 3 .
The primary reaction promoted in gasification zone of the rotary kiln 1 is the gasification of residual carbon present in the devolatalized and partially combusted biomass and which is represented by:
Carbon Steam Reaction
C+H2O+Heatlwdarw.CO+H2
When the fuel gas exits the fuel gas outlet 4 , the temperature of the gas would be 1700 to 1900 deg F. and the fuel gas would be made up mostly of C, CO2, H2, N2, H2O, and CH4. Some traces of impurities such as ammonia, hydrogen chloride, and hydrogen sulfide may also be present. These impurities will be washed down by a suitable chemical scrubber prior to using the fuel gas.
FIG. 3 is a depiction of one of many possible nozzle arrangements that is provided at the bottom of each of the interior section 9 , 10 , 11 , and 12 of the gas distribution port 3 . The total area of the plurality of the nozzles 21 , 22 , 23 , and 24 corresponding to each of the interior section 9 , 10 , 11 , and 12 corresponds with the area of the conduits 13 , 14 , 15 , and 16 that communicates each of the interior sections 9 , 10 , 11 , and 12 with the corresponding reactant gas supply. This way the reactant gases are introduced to the interior of the rotary kiln without significant loss of pressure.
FIG. 4 is a cross section of one of the four sections 10 of the gas distribution port 3 to illustrate the circumferential confinement of the plurality of the nozzles 22 . For best results, the nozzles are confined within the bottom third circumference of the conduit of the gas distribution port 25 and disbursed all along the length of the interior section of the gas distribution port 3 . The circumferential confinement of the nozzles 25 is largely dependent upon the thickness layer of solids 27 present at the bottom of the refractory lined rotary kiln 6 and the relative positioning of the gas distribution port 3 because as preferred embodiment of this invention, all of the nozzles 21 , 22 , 23 , and 24 are embedded within the layer of solids 26 that are processed in the rotary kiln 1 . The circumferential confinement for the nozzle can be extended or reduced from one third of the circumference for specific applications to meet the condition of embedding all of the nozzles within the solid layer at the bottom of the rotary kiln. The positioning of the conduits 13 , 14 , 15 , and 16 within the corresponding sections 9 , 10 , 11 , and 12 of the gas distribution port are not critical as long as they communicate unhampered with the corresponding reactant gas supplies.
FIG. 5 is merely an expanded view of the cross section of one of the section 10 of the gas distribution port 3 .
FIG. 6 is a depiction of typical temperature profile inside of the rotary kiln 1 when it is used as biomass gasifier. The maximum temperature is reached in the combustion/gasification section of the kiln.
The present invention is also useful when practiced as combustor instead of gasification. In this case, only air and/or oxygen is used for reactant gas in all sections 9 , 10 , 11 , and 12 of the gas distribution port 3 . The amount of air or oxygen introduced will commensurate with the combustor capacity with respect to the carbonaceous material being combusted. The principles stated with respect to nozzle locations, spacing, and orientation as well as the gas flow in each of the sections 9 , 10 , 11 , and 12 will be somewhat different than in the case of the gasification in order to attain complete combustion of the carbonaceous material as well as to maintain suitable temperatures within the rotary kiln.
For person familiar with the art of gasification and combustion will recognize that for gasification, the amount of air or oxygen introduced into the gasifier 1 is less than fifty percent of the stoichiometric requirement for the complete combustion of the carbonaceous material being gasified whereas in the case of complete combustion, the amount of air introduced into the kiln reactor 1 sometimes exceeds 200 percent of the stoichiometric requirement of the complete combustion of the carbonaceous material to modulate the temperature inside the rotary kiln and also depending upon the specified exit temperature for the outlet gas in the gas outlet 4 .
The present invention has several advantages.
One advantage is that by allowing intimate contact between gas and carbonaceous solids within the kiln gasifier, it is possible to obtain complete utilization of the carbonaceous material.
Another advantage is that by allowing intimate contact between the gas and the solids in the vicinity of heated refractory lining of the kiln, the drying, devolatalization, partial combustion, and gasification reactions of the carbonaceous material with reactant gases occur much more rapidly since the requisite heat for gasification is provided by the heat retained by the refractory lining as well as by the partial combustion of the carbonaceous material.
Yet another advantage is rotation of the gas distributor which enables added turbulence at the wall of the rotary kiln gasifier thereby increasing the interaction between gas and the solids for attaining optimal reaction and better utilization of carbonaceous material.
Whilst the invention has been described in detail in terms of specific embodiment thereof, it will be apparent that various changes and modifications can be made by one skilled in the art without deviating from the spirit and scope thereof. One skilled in art will also realize that this invention is applicable for broad range of solids processing in the rotary kiln, all of which are included by inference.
REFERENCES
1. J. H. Howson and K. Casnello “Risk Reduction Measures for the Development of Biomass Rotary Kiln Gasification,” Report No. ETSU B/U1/00646/REP and DTI/Pub URN 02/754, issued by DTI Sustainable Energy Programmes for CPL Industries, 2002.
2. G. P. Androutsopoulos, K. S. Hatzilyberis, “Electricity Generation And Atmospheric Pollution The Role Of Solid Fuels Gasification” presented at 7th International Conference on Environmental Science and Technology Ermoupolis, Syros island, Greece, September 2001
3. Francesco Fantozzi, Bruno D'Alessandro, and Umberto Desideri, “An IPRP (Integrated Pyrolysis Regenerated Plant) Microscale Demonstrative Unit in Central Italy” Proceedings of ASME Turbo Expo 2007: Power for Land, Sea and Air, May 14-17, 2007, Montreal, Canada
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A port assembly for controlling the delivery of gases into the horizontal rotating reactor such as kiln gasifier is disclosed for introducing reactant gases. The port assembly comprises a cylindrical conduit is divided into noncommunicating four or more sections extending through the entire length of the kiln and supported by the stationary end plates of the rotating kiln gasifier. Each section of the conduit communicates with external supply of the reactant gases and each supply of reactant gases is independently controlled in terms of the composition and quantity. Each section of the port assembly communicates with the interior of the kiln gasifier through the plurality of nozzles are confined in the lower part of the conduit. The number and the size of the nozzles in individual section of the conduit is based on the desired flow of gases and available pressure for the supply of the reactant gases.
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RELATED APPLICATIONS
[0001] This application claims priority benefit of U.S. Ser. No. 60/647,354 filed Jan. 25, 2005.
BACKGROUND OF THE INVENTION
[0002] a) Field of the Invention
[0003] The present embodiment relates to the field of apparel, and or particularly to the class of apparel including panty hose nylon stockings and other items of hosiery. Also, it relates to a device and process for preserving the usable life of hosiery.
[0004] b) Background Art
[0005] A general description of the use of hosiery, stockings, or nylon type material will be briefly discussed. Stockings, hosiery, or tights, made of nylon and/or spandex, are coverings used by women to fit the body from the waist to the feet.
[0006] Hosiery is worn by women for many reasons. The stockings can enhance the curve of the legs through the sheerness, making the legs look smoother. They can also outline shape of the leg through the use of dark colors. The stockings also can provide warmth in colder weather.
[0007] Stockings come in a wide range of styles which generally relate to thickness and color. The thinner the stocking the shearer or finer the smoothness of the leg appearance.
[0008] Congruent with the thinness, is the likelihood that the stocking will develop rips or tears because of the thin structure of the weave.
[0009] The stocking weave is generally composed of nylon fibers and/or spandex fibers. The spandex provides the elasticity, while the nylon provides some elasticity as well as the thinness of the structure. The tearing or running of the stocking is most common with a higher content of nylon and a thinner structure.
[0010] The nylon and spandex fibers as stated before have a certain amount of elasticity which corresponds to a certain linear distance the fiber can be stretched without leading to permanent deformation.
[0011] When not in use, the nylon and spandex fibers of the hosiery are in a nonelastic state of use. When the user puts on the nylon stockings, the nylon and spandex fibers are stretched to fit the outer circumference of the user's leg. Although the nylon or spandex fibers are still within the elastic range, the cross-sectional area of the stretched fibers has decreased and is more susceptible to failure due to the transverse force as applied by a sharp object of some sort. This transverse force from a sharp object will likely cause a hole in the hosiery, which occurs where one or more of the nylon or spandex fibers has failed causing the elastic tension force within the failed nylon or spandex fibers to be transferred to the surrounding non-failed fibers.
[0012] Even though the tear or hole may start in a number of different ways, once it has started it is difficult to prevent the tear from continuing further. To prevent this tearing, there have been a number of solutions provided. One is to use off the shelf nail polish when generally applied at the apex of the tear or at the point where the tear is about to continue will help stop the tear.
[0013] The applicator itself may not be configured to apply a uniform and consistent amount of nail polish onto the tear. Also, nail polish takes time to dry. Much of the solution may not adhere to the material because the stocking itself is thin and not very absorbent.
[0014] Consequently the application of the nail polish liquid needs to be uniform and consistent, reinforcing the surrounding fiber structures, and if possible, breaching the failed fiber members to provide a patch to enable supplemental transferring of the tension load across the breached portion and also providing additional reinforcement to the surrounding fiber members.
[0015] The following patents are related to the problem of fixing or preventing hosiery tears.
[0016] U.S. Pat. No. 5,338,784 is directed primarily to the particular composition which is used as the repair liquid. The composition contains nitrocellulose, resin, another ingredient, and also a solvent. In column three (3) beginning on line 7 and following, it states that it could be stored in a jar with a brush, a roll-on bottle, any type of bottle, etc.
[0017] U.S. Pat. No. 4,994,127 describes a method of mending runs, snags, holes or the like in hosiery where there is “one-shot application container” containing the liquid adhesive ingredient. It also indicates that decorative material such as dyes, glitter, etc. could be used.
[0018] U.S. Pat. No. 5,087,496, shows a self-adhesive device which is attached to the damaged hosiery by Velcro means.
[0019] U.S. Pat. No. 4,068,322, discloses an adhesive patch that is placed on either side of the damaged area to prevent further damage.
[0020] In addition, a search of the internet uncovered a site that calls itself “PANTYHOSE ENCYCLOPEDIA”, which contains the statement, “The Miracle Against Runs! Just put some nail polish around the run and your pantyhose is saved.” Also, there was uncovered a New York Times publication concerning the care of pantyhose and the five (5) pages of that article are provided in the prior art statement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is an overall environmental perspective view of the nylon hosiery with a tear;
[0022] FIG. 2 is an enlarged view of the hosiery;
[0023] FIG. 3 is a plan view of the hosiery and the woven fiber members with a tear;
[0024] FIG. 4A is an enlarged view of the nylon fiber members and the forces acting upon them during a tearing situation;
[0025] FIG. 4B is an enlarged plan view of the nylon fiber members with the forces normalized;
[0026] FIG. 5A is an enlarged plan view of the hosiery tear with a binding solution zone;
[0027] FIG. 5B is a cross-sectional view of the stressed fiber members reinforced by the binding composition;
[0028] FIG. 6 is a perspective view of a first embodiment;
[0029] FIG. 6B is an enlarged perspective view of the user holding a first embodiment and applying the solution to a predetermined circumferential solution zone;
[0030] FIG. 6C is an alternative embodiment of the present embodiment's solution application head;
[0031] FIG. 6D is an alternative embodiment of the solution applicator head;
[0032] FIG. 7 is an alternative perspective view of the solution applicator with a disposable insert.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] In discussing the detailed description of the current embodiment it is preferable to first provide a detailed description of the structure and function of the nylon fabric, thus providing a clear understanding of the current embodiment environment.
[0034] With this in mind, a detailed description of the fabric structure and function will be provided, followed by a detailed description of the current embodiment of the hose run stopper method and apparatus which includes the apparatus container or applicator, its application elements, and the binding composition which when applied, reinforces the nylon fabric. Lastly, additional embodiments of the applicator elements will be provided.
[0035] Referring to FIG. 1 , the user may be wearing nylon fabric hosiery 14 on her leg 12 . Generally, the tear is caused by a snag from a sharp object, which brushes up against the user's leg 12 . Stopping a tear in the hosiery is difficult given the specific mechanics and structure of the typical nylon hosiery.
[0036] Although the run or tear 16 caused by the snag on the object may be unnoticeable because of the relatively fine weave of the hosiery 14 , once the balanced structure has been disturbed, a tear 16 will quickly develop, and for reasons discussed below, the tear may irreparably harm the hosiery 14 , making it unusable.
[0037] Still referring to FIG. 1 , the typical nylon stocking 14 is worn on the leg 12 , the leg having a longitudinal axis 24 and a circumferential axis 26 . The fibers of the nylon stocking 14 run in both the longitudinal axial direction 24 and the circumferential axial direction 26 . Referring to FIG. 2 , a magnified version of the tear 16 is shown within the hosiery 14 , where the user is applying the current embodiment as discussed below.
[0038] The weave of the stocking will now be discussed. Referring to FIG. 3 , the nylon stocking fiber members are shown equally spaced along the longitudinal axis 24 , as well as the circumferential axis 26 of the user's leg. Further, the nylon stocking fibers are shown in tension, or in other words are shown after the user has put the hosiery stockings 14 on and have been stretched around the circumference of the user's leg. The nylon fabric has a series of longitudinal fiber members 36 as well as a series of generally perpendicular to the longitudinal plane, circumferential fiber members 30 . During normal wear, the circumferential fiber members are stretched around the outer surface area of the user's appendage or leg 12 a specific distance or circumferential stretch distance 34 which is dependent upon the user's leg size. Directly proportional to the circumferential stretch distance 34 is the amount of elastic tension force 32 applied to the individual circumferential fiber members 30 . The longitudinal fiber members 36 are also tensioned along the longitudinal length of the user's leg.
[0039] After the snag has occurred, and still referring to FIG. 3 , the nylon hosiery 14 will, develop a rip or tear 16 . Once the hole is created, the tensioned circumferential fiber members 30 act to pull the tear 16 further apart. This force creates the run. As mentioned before, the tear 16 is proportional in size to the circumferential stretch distance 34 . After the elastic circumferential tension force 32 has pulled the longitudinal fiber members 36 to the proximate circumferential stretch distance 34 , the circumferential fiber members 30 , are in an untensioned resting state or in other words are untensioned fiber members 44 .
[0040] The tear 16 has parallel longitudinal border fiber members 49 as well as two apex points 47 at the beginning and end of the tear 16 . It is at the apex point 47 where the elastic tension force 32 residing in the circumferential fiber members 30 pulls the connected longitudinal fiber members 36 apart and continues the tear 16 .
[0041] Now describing in particular the tearing or ripping action. As the longitudinal fiber members 36 are pulled away from their existing longitudinal location towards the parallel longitudinal border fiber members 49 , the circumferential fiber members 30 are transitioning from the tension state to the untensioned state and act on this longitudinal fiber member 36 to create a resultant angular tension member 42 pulling on the individual circumferential fiber members 30 at the apex point 47 of the tear 16 .
[0042] Referring to FIG. 4A , a simplified version of this action is shown with a single circumferential fiber member 30 having an existing elastic tension force 32 applied. Also on the upper longitudinal portion of the stocking, the longitudinal fiber members 36 are shown running longitudinally. At the lower longitudinal portion of the stocking below the circumferential fiber members 30 are two longitudinal fiber members 31 being pulled towards the longitudinal border fiber member position 49 . Along the axis of these transitioning longitudinal fiber members 31 is a resultant angular tension force 42 .
[0043] This resultant tension force 42 has a longitudinal tension component 40 and circumferential tension component 38 . For calculation purposes, we will assume that the circumferential tension component 38 is one half of the tension force 32 , while the longitudinal tension component 40 is some other force amount which results in combination with the circumferential tension component 38 to produce the resultant angular tension force 42 as shown.
[0044] The origin 33 of this resultant angular tension force 42 is the intersection, or connection of the longitudinal fiber members 36 and the circumferential fiber member 30 . Simplifying the force diagram, and referring to FIG. 4B , the circumferential tension component 38 can be combined with the original circumferential tension force 32 in both the positive and negative axial circumferential directions to provide a total circumferential tension force 48 . This total circumferential tension force 48 acts to further stress the immediate circumferential fiber member 30 , reducing its cross-sectional area, and concurrently reducing its capacity to resist shear stresses. Combined with the two longitudinal tension component's 40 acting cross-sectionally at the origin 33 , the circumferential fiber member 30 tends to fail. Therefore the same resultant tension force 42 is applied to the next circumferential fiber member 30 in the longitudinal direction, creating a chain reaction of fiber member failures.
[0045] This series of chain reaction failures of the fiber members can occur gradually or nearly instantaneously, depending on the size of the user's leg as well as the flexing of the user's muscle, thus increasing the circumferential distance and increasing the circumferential tension force, stressing the fibers beyond their elastic range.
[0046] Therefore, it is desirable to have a solution or composition contained within an applicator, which when the solution is applied to the tear 16 , binds to the fiber members, reinforcing them at the weakened stress point, as well as drying or binding quickly to the fiber members.
[0047] Also, it is highly likely that the user is wearing the hosiery to work or at a social function, and needs an applicator which can provide accuracy of the application of the binding solution to the tear, as well as convenience in use.
[0048] Therefore the discussion of the current embodiment acting in the above described nylon hosiery environment will first describe the elements of the applicator, followed by the elements of a typical binding solution, and lastly, additional embodiments of the applicator will be discussed.
[0049] The solution applicator 10 , as referred to in FIG. 6 , is configured to provide ease of handling as well as portability. In this current embodiment, the solution applicator 10 is shown as a generally cylindrical tube with a top and bottom as well as an inner region and an application tip. The application tip is covered by a cap. Although this embodiment shows a cylindrical configuration, other ergonomically designed configurations to easily fit within the user's hand are could be used. These other ergonomically designed configurations can include an elliptical configuration, a rectangular configuration, or a series of configurations designed to fit within the palm of the hand. Such configurations could also include an oval type applicator with two parallel walls and a perimeter sidewall connecting the two parallel walls, but for current discussion purposes the cylindrical shell will be discussed.
[0050] Still referring to FIG. 6 , the solution applicator 10 is shown in this embodiment, with a cylindrical shell 50 holding the binding solution 58 . The cylindrical shell is arranged along a vertical axis 80 and a radial axis 82 . In the vertical direction, the cylindrical shell 50 has a height in the existing embodiment of 3 ½ inches; other lengths can be provided, such as a shell having a longer vertical length of 5 inches, and a lesser radial dimension. The cylindrical shell has an inner surface 51 , and an outer surface 49 . At the base of the cylindrical shell 50 is a bottom wall 52 which seals off the inner region 53 of the cylindrical shell 50 .
[0051] At the top portion of the solution applicator 10 is an application head 60 which is fashioned in the current embodiment, from a porous or sponge like material. In the current embodiment, the sponge like material is a commercially available material with a porous cellular structure large enough to carry the solution and be sufficiently compressible to discharge the solution. This sponge like material is well-known in the art and is used commercially in many different applications. Use of the sponge like material allows the binding solution 58 contained within the solution applicator 10 to migrate up through the application head 60 and be absorbed into the cells of the material for application.
[0052] Still referring to FIG. 6 , various shapes of the application head 60 can be provided for accurate application of the binding solution 58 to the fiber material 14 as discussed in the alternative embodiments below. The application head 60 in the current embodiment is fashioned in a cylindrical shape having an outer cylindrical surface 62 as well as a top application surface 66 and a bottom absorbing surface 68 . The top application surface 66 is within the horizontal radial plane 82 of the solution applicator 10 . By having a flat top application surface 66 , the user can apply a uniform amount of binding solution 58 to the hosiery 14 within a predefined circumferential solution zone 61 as seen in FIG. 6 B. In this current embodiment the outer diameter of the cylindrical shell is approximately¼ of an inch, and the outer diameter of the application head is also approximately¼ of an inch. The application head has a vertical height of approximately⅜ of an inch, and has a general configuration of a cylindrical shape similar to that of the solution applicator.
[0053] By using the flat top application surface 66 , the user a more uniform application which could compromise the effectiveness of the applicator. In contrast, a user could use an edge of the application head to be more specific in the application of the solution to the nylon tear.
[0054] A sealed environment to keep the solution in the containing region from escaping is desirable. Referring back to FIG. 6 , the outer diameter 64 of the application head 60 is at least the same size as the cylindrical shell inner diameter 56 . The bottom portion of the application head 60 is placed down into the top portion of the cylindrical shell 50 . This creates a tightly sealed environment where the binding solution 50 cannot escape the inner chamber region 53 of the solution applicator 10 without first passing through the porous elastomer material. The porous elastomer material of the application head 60 acts as a sponge to absorb a predetermined amount of binding solution 58 . This absorption occurs in one form by capillary action.
[0055] For reasons discussed below, the binding solution has an alcohol-based content, and will readily evaporate. Therefore, to keep the absorbed binding solution 58 from evaporating and thus binding within the porous elastomer material 60 , a closure cap 62 is provided to create a hermetically sealed environment thus preventing the binding solution from evaporating out of the cylindrical shell inner region 53 .
[0056] An additional embodiment of this solution applicator 10 is that the inner region 53 of the cylindrical shell 50 is nearly 100% hermetically sealed from the outside environment when the cap 61 is attached over the application head. When initially used, the inner region 53 is completely full of binding solution 58 . After a period of time, there becomes a void or air space within the inner region 53 due to the consumption or use of the solution.
[0057] Thus, the binding solution 58 contained within the inner region 53 will not take up the entire volume of the inner region 53 , thus leaving a volume space for potential evaporation. A vapor volume region 61 will develop, and become filled with a combination of air and evaporating binding solution vapor. This combination of air and binding solution vapor will act to mitigate any hardening of the binding solution 58 on or in the cellular structure of the sponge like material as well as within the cylindrical shell 50 itself. Similarly, when the solution applicator cap 62 is on the solution applicator 10 , virtually no airspace is left between the cap top 65 and the top application surface 66 . What little airspace there is left will be filled with a mixture of oxygen and binding solution vapor, and the evaporation rate of the binding solution from the top application surface 66 will balance out to nearly zero, thus keeping the application head 60 moist with the binding solution 58 .
[0058] In this particular embodiment, the cylindrical cap 62 has a height substantially great enough to cover the application head 60 and be secured to the outer wall of the cylindrical shell 49 through one of many securing means. One such securing means is a screw type cap with grooves fabricated into the cylindrical shell outer wall 49 and corresponding grooves inside the cylindrical cap 62 .
[0059] A brief discussion of the application process of the binding solution 50 to the hosiery 14 will now be provided.
[0060] Referring to FIG. 6B , the solution applicator 10 holding the binding solution is shown in its pre-application state where the user has positioned the applicator head 60 just above a tear 16 in the hosiery 14 .
[0061] Still referring to FIG. 6B , the user presses the solution applicator 10 against the hosiery tear 48 and depending upon the amount of binding solution 58 desired to cover the rip zone 48 as well as the surrounding fiber members, the user will apply either a greater or lesser compression force downward on the solution applicator 10 thus creating a surface engagement between the top applicator surface 66 and the hosiery or nylon stockings 14 . The corresponding compression of the sponge application head 60 reduces the containing volume 70 and forces the binding solution 58 onto the hosiery 14 .
[0062] After the application process has been performed, the binding solution 58 will harden around the individual fiber members adjacent to the tear zone and reinforce the fiber members within the path of the tearing chain reaction to resist the additional tension and shear forces.
[0063] A detailed description of the fiber members as reinforced by the binding solution will now be provided.
[0064] Referring to FIGS. 5A and 5B , one embodiment of the binding solution zone 61 is shown. The binding solution 58 as applied to the nylon stocking 14 at the apex 47 of the tear 16 has a circumferential outer boundary line which is the outer limits of the applied binding solution 58 . After a period of time, the binding solution 58 evaporates to form a binding composition 90 . In a first form, the flexible binding composition only surrounds and reinforces the circumferential fiber members 30 and the longitudinal fiber members 36 . This binding composition 90 may in a second form fill the fiber cells 46 in addition to surrounding the circumferential fiber members 30 and the longitudinal fiber members 36 . In such a form, the binding composition 90 can also span between the parallel longitudinal border fiber members 49 of the tear 16 , thus reestablishing the circumferential tension capacity of the broken circumferential fiber members 30 .
[0065] Referring to FIG. 5B , the circumferential fiber members 30 as well as the longitudinal fiber members 36 are shown in cross-section with the binding composition 90 applied and surrounding the tensioned members 30 and 36 . Because of the additional tension, the fiber members 36 have a reduced cross-sectional area. The binding composition 90 surrounding the tensioned members 30 and 36 , adds additional tensile capacity to the individual circumferential fiber members 30 , as well as distributes the tension force to the surrounding circumferential fiber members 30 and longitudinal fiber members 36 . Further, the origin 33 , FIG. 5A , is also reinforced substantially in both the longitudinal and circumferential direction's by the binding solution 58 . Thus, when the resultant angular tension force 42 , FIG. 4A , is applied to the origin point 33 , the reinforced members adequately resist potential failure.
[0066] By using a uniform top application surface 66 during application of the binding solution, the user can be assured a uniform amount of solution is applied to all of the surrounding fiber members, thus providing uniform reinforcement and distribution of the load around the apex 47 of the tear 16 .
[0067] A detailed description of the binding solution 58 will now be provided. The binding solution 58 should have characteristics which include elasticity for stretching along with the nylon fiber members, binding properties to attach to the nylon fibers, and a high rate of evaporation so as to minimize wait time. The physical characteristics of the binding solution 58 can be composed of a natural resin which dries to a hard but flexible and durable compound after application. This compound can easily bind with the fibers in a nylon or spandex and nylon hosiery stocking.
[0068] The current embodiment of the binding solution 58 is comprised of four parts of a commercially available nail polish compound and one part of a thinning solvent. In this embodiment, the four parts nail polish compound has the following chemical composition by percentage of weight.
4 parts Nail Polish Nail Polish Compound % Compound Composition by Weight Nitrocellulose 12.5% Toluene-sulfonamide- 10% formaldehyde resin Camphor 3% Dibutyl phthalate 5% ethlyl acetate 25% butyl acetate 23.5% toluene 20% titanium dioxide 0.5% amaranth 0.5% total 100%
[0069] Additionally, in this embodiment the one part thinning solvent has the following chemical composition by percentage of weight.
Thinning Solvent % Composition 1 part Thining Solvent by Weight Nitrocellulose 0% Toluene-sulfonamide- 0% formaldehyde resin Camphor 0% Dibutyl phthalate 0% ethyl acetate 70.6% butyl acetate 0% toluene 0% titanium dioxide 0% amaranth 0% ethyl alcohol 17.4% water 12% total 100%
[0070] Lastly, in combination the binding solution 58 from four parts Nail Polish compound, and one part thinning solvent, has the following chemical composition by percentage of weight.
Flexible Bindinq Compound % Composition by Weight Nitrocellulose 10% Toluene-sulfonamide- 8% formaldehyde resin Camphor 2.4% Dibutyl phthalate 4% ethlyl acetate 34.12% butyl acetate 18.8% toluene 16% titanium dioxide 0.4% amaranth 0.4% ethyl alcohol 3.48% water 2.4% total 100%
[0071] For reasons discussed above the application of this binding solution to the nylon stockings 14 around the tear 16 from the snag as shown in FIG. 2 prevents the nylon stockings 14 from being ruined.
[0072] A discussion of alternative embodiment of the application head 60 will now be provided in FIGS. 6C and 6D and a discussion of an alternative configuration of the solution applicator 10 will be discussed in FIG. 7 .
[0073] Referring to FIG. 6C , in an alternative embodiment, the porous elastomer material application head 60 has a uniform angular application plane 166 , where the application plane 166 is cut at an angle 168 from the radial axis plane 82 to allow for customization of the application process of the application head 60 to the nylon stockings 14 . Depending on the desired configuration of the application head 60 , the uniform angular application plane 166 could be manufactured from an angle 168 ranging from 0° to 90° from the radial axis plane 82 .
[0074] Additionally, in another alternative embodiment, referring to FIG. 6D , the application head 60 is shown configured in a semi-spherical shape 170 . This semi spherical shape 170 enables the user to apply increasing amounts of binding solution 58 within ever-increasing amounts of application zones 172 , congruent with the amount of downward force being applied by the user to the solution applicator 10 . As the force increases, the elastomeric semi-spherical application head 60 is further depressed, thus covering a greater area and discharging more binding solution 58 .
[0075] Thus, if the tear 16 , FIG. 6B , is relatively minor, the user may choose to apply a minimal amount of the binding solution 58 by dabbing the hosiery tear 16 with the semi-spherical application tip 174 . If the tear 48 is large or is under large tension stresses, the user may choose to apply a greater amount of the binding solution 58 by pressing the porous elastomer application head 60 firmly onto the hosiery 14 . Thus, the semi-spherical application shape 170 provides the user one option in applying varying amounts of the binding solution 58 the hosiery tear 48 .
[0076] Referring to FIG. 7 , in an alternative embodiment, the solution applicator 10 is provided with a disposable insert section 200 which allows the user to refill the solution applicator 10 with a new recharged binding solution section. The disposable insert section 200 , in the alternative embodiment, has the application head 60 as well as male threads 210 and contains the binding solution 58 within the solution containment region 212 . The solution containment region 212 is configured cylindrically to fit within the cylindrical shell 50 of the solution applicator 10 . The cylindrical shell 50 of the solution applicator 10 has female insert inner threads 216 which correspond to the male threads 210 of the disposable insert 200 . After the user disposes of the used insert, she can installed the recharged disposable binding solution insert 200 and then secure the cap 62 over the application head 60 to hermetically seal the solution applicator 10 . Additionally, the disposable insert 200 can have varying application head configurations, as discussed previously.
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A pantyhose or hosiery reinforcing tool. The tool reinforces the elastic fibers surrounding a tear within the hosiery. The reinforcing tool has a cylindrical containing tube which holds a specific amount of flexible binding solution. The flexible binding solution is in liquid form and is soaked into a porous elastomer material which has a thin wall cell structure to absorb the flexible binding solution. Projecting out of the top of the cylindrical containing tube is an application head which is either cylindrical in shape or hemispherical in shape. The application head is composed of the same porous elastomer material. A top fits over the application head and screws tightly in one form to the cylindrical tube during storage. In application, the application head of the reinforcing tool is pressed against the leading edge of the tear applying the flexible binding solution. The flexible binding dries quickly to reinforce the hosiery elastic fibers.
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STATEMENT OF RELATED CASES
This application is a continuation-in-part of application Ser. No. 129,713 filed Dec. 7, 1987 and also entitled "Inflow Cannula For Intravascular Blood Pumps" now abandoned.
FIELD OF THE INVENTION
This invention relates to an inflow cannula for blind insertion of an intravascular blood pump, and more particularly to a cannula with a beveled tip which pushes the cannula to the center of the aortic valve for retrograde traversal.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,625,712 and copending application Ser. No. 129,7l4 filed 12/07/87 disclose miniature high-speed blood pumps which can be threaded through a blood vessel to provide heart assist in emergency situations without major surgery. Typically, such pumps are inserted through, e.g., the femoral artery. An inflow cannula is positioned ahead of the pump during insertion, and this cannula must typically be pushed through the aortic valve in a retrograde direction.
In the past, such retrograde insertion was usually done by means of a wire guide over which the inflow cannula was slipped, and which was subsequently withdrawn. This method was unsatisfactory not only because it was awkward and carried a risk of injury to the vascular system and to the aortic valve, but also because it required the continuing observation of the wire during insertion by x-ray or other procedures. In an emergency, appropriate x-ray equipment may not be immediately available, and heart assist may have to be provided so quickly that the slow wire guide method may not be suitable.
A requirement therefore exists for an inflow cannula which can be attached to the intake of an intravascular blood pump and can be pushed ahead of the pump for blind retrograde insertion into the left ventricle through the aortic valve without any additional apparatus and without danger of injury to the patient.
SUMMARY OF THE INVENTION
The present invention fulfills this requirement by providing a wire-reinforced silicon rubber cannula which has a spring-loaded curve built into it. This curve allows a reliable traverse of the aortic arch without getting the cannula caught in a major vessel such as, e.g., the left subclavian artery. The cannula of this invention carries at its leading end a soft, beveled tip which is so positioned with respect to the built-in curve that the tip tends to point inwardly of the curve.
The softness of the tip material and the elongated bevel of the tip, which forms a pair of elongated shoulders of increasing depth extending transversely of the cannula axis between the distal and proximal ends of the tip, combine to make the tip bend near the proximal end of the beveled section, backward or forward, in a direction generally normal to the plane of the bevel, when it presses against an obstacle.
As the tip approaches the aortic valve, one of two things occur: if the tip is centered with respect to the aortic valve, and the valve is open (as during systole) as the tip is pushed through it, the tip passes through the aortic valve without deformation. If, however, the valve is closed (as during diastole), or if the tip is substantially off center, its distal end may slide into a sinus of the aortic valve.
When this happens, the distal end of the tip, due to the beveled shape of the tip, folds forward or backward upon itself about a line generally in the bevel plane. In so doing, it tends to push the body of the cannula toward the center of the valve annulus. Due to the bowl shape of the sinuses, the tip end tends to slide toward their center, and the folding of the tip end tends to position the distal end of the cannula over a commisure of the aortic valve, where it can easily penetrate without injury to the sinuses.
As a practical matter, the physician may move and twist the cannula back and forth if it appears that the flexible tip is catching in a sinus. Successful penetration at a commisure or in the center of the annulus occurs easily due to the spring action of the cannula (which was longitudinally compressed by pushing against the sinus) as soon as a valve leaflet is pushed aside or the valve opens on systole.
After the cannula has entered the left ventricle, the flexible tip springs back to its original shape and allows blood to flow into the cannula without obstruction. Apertures are provided in the side of the cannula adjacent its distal end to prevent occlusion of the cannula intake by the flexible tip as a result of the pump's suction.
The considerable softness of the tip prevents irritation of the ventricle (e.g. tickling which can cause arrythmia, fibrillations, or premature ventricular contractions); yet the tip is stiff enough to bend or fold neatly without rolling or telescoping. The flat shape of the distal end of the tip prevents it from entering the coronary ostia if it slides into the sinuses.
It is therefore the object of this invention to provide an inflow cannula for intravascular blood pumps which is suitable for blind retrograde insertion into the left ventricle of the heart through the aortic valve without substantial risk of injury.
It is another object of the invention to accomplish this purpose by using a cannula with a spring-loaded curve and a soft, flexible tip which is beveled toward the inside of the curve and is capable of temporarily folding upon itself upon encountering the aortic valve so as to center the cannula for penetration through the aortic valve.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating the use of the invention in the arterial system of a patient;
FIG. 2 is a plan view of the cannula of this invention;
FIG. 3 is a side elevation of the tip of the cannula of FIG. 2;
FIG. 4 is a transverse section of the distal tip of the cannula along line 4--4 of FIG. 3;
FIG. 5 is a front elevation of the distal tip of the cannula of FIG. 3 in its forwardly folded position;
FIG. 6 is a side elevation of the tip in the position of FIG. 5;
FIG. 7 is a side elevation corresponding to FIG. 6 but showing the tip in the rearwardly folded position; and
FIG. 8 is a vertical section of the arotic valve showing passage of the cannula during systole;
FIG. 9 is a vertical section of the aortic valve showing an off-center approach of the cannula during diastole;
FIG. 10 is a vertical section of the arotic valve showing entry of the cannula tip into a sinus during diastole;
FIG. 11 is a plan view of the aortic valve along line 11--11 of FIG. 10; and
FIG. 12 is a vertical section of the aortic valve showing penetration of the cannula following the condition of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows, in schematic form, the environment in which the invention is used. When heart assist is needed in an emergency or for other medical reasons, a miniature intravascular blood pump 10 is percutaneously inserted into the femoral artery (not shown) and is pushed through the femoral artery into the aorta 12. Rotary power for the cable drive 13 of pump 10 and purge fluid for its hydrostatic bearings is supplied through a catheter 14 from outside the patient's body, as described in more detail in copending application Ser. No. 129,7l4 filed 12/07/87. The cannula 16 of this invention is attached to the distal (i.e. intake) end of the pump 10 and guides it through the patient's arterial system during insertion.
In order to assure a steady blood flow through the pump 10, it is desirable to locate the blood intake in the left ventricle 17 of the heart; i.e. the distal end of the inflow cannula 16 must be passed through the aortic valve 18. This poses several problems, particularly in emergency situations where no x-ray equipment is readily available to track the insertion of the cannula 16. To begin with, the cannula 16 must follow the aortic arch 20 smoothly without getting caught in one of the major arteries 24 branching off from the aorta 12 in the arch 20. Next, the cannula 16 must be substantially centered in the aorta 13 as it approaches the aortic valve 18 so as not to get caught in or injure the sinuses 28 (FIG. 11) while penetrating through the valve 18 or pushing aside the aortic leaflets 30. Finally, once the cannula 16 has passed through the aortic valve 18, its inflow opening must be completely unobstructed. All of these procedures must, of course, be accomplished with minimal risk of injury to the patient's vascular system. In addition, once the cannula is in place in the heart, it must not irritate or tickle the ventricle wall for fear of producing arrythmia, fibrillations, or premature ventricular contractions, or mechanical endocardial injury.
FIGS. 2 and 3 show the inventive cannula structure which fulfills these requirements. The cannula 16 is formed from a tube 32 of soft silicon rubber which, in its body section 34, covers a spring 36. The tip section 38 of the cannula 16 beyond the distal end of spring 36 is beveled for a purpose described below. A radioopaque strip 40 may be interposed between the tube 32 and the spring 36, and extended to the distal end of the tip section 38, for x-ray tracking of the cannula insertion when x-ray equipment is available.
In accordance with one aspect of the invention, conventional forming techniques are employed to bias the body section 34 of cannula 16 into the arcuate shape best illustrated in FIG. 2. This bias urges the cannula 16 to follow the curve of the aortic arch 20 upon insertion and keeps it away from the branch arteries while it traverses the aortic arch. Of course, the loading imposed by spring 36 is weak enough to allow the body section 34 to be straightened by the walls of the arteries when it traverses a straight section of artery.
On each end of its arcuate portion, the body section 34 has short straight portions 42,44. The proximal straight portion 42 may be attached to the intake end of pump 10 in any conventional manner, and the distal straight portion 44 allows the intake opening 46 to remain centered in the left ventricle 17 (FIG. 1) after traversing the aortic valve 18. As a general indication of the parameters of the cannula 16, its diameter may be on the order of 7 mm; the arcuate portion of the body section 34 may have a radius on the order of 2.5 cm; the straight portion 42 may be on the order of 10 cm long; and the straight portion 44 may have a length on the order of 4 mm, not counting the 4 cm-long tip section 38. As best shown in FIG. 3, the tip section 38 is beveled at its distal end along a bevel plane 50 lying at about a 20° angle to the tip's axis. A pair of auxiliary openings 48 are provided in the side of tip section 38, and the distal end 47 of the tip section 38 is cut off flat as best shown in FIG. 2, for purposes discussed below.
FIGS. 8 through 12 show in more detail what happens as the tip section 38 contacts the aortic valve 18 when moving in the direction of arrow 45. If the aortic valve 18 is open (as during systole, FIG. 8) and the tip 38 is reasonably centered as it approaches the valve 18, it passes through the valve 18 unaltered. If, however, the valve 18 is closed (as during diastole, FIG. 9), or if the tip 38 approaches it substantially off center, the flat distal extremity 47 (FIG. 2) of tip 38 contacts one of the aortic leaflets 30 and slides down its side into the sinus 28. If the sinus 28 is one into which a coronary ostium opens, the flat shape and width of the tip extremity 47 prevents the tip 38 from entering the ostium 49 (FIG. 11).
The beveling of the tip 38 along plane 50 results in the formation of shoulders 51 (FIG. 4) between the distal and proximal ends of tip section 38. When the soft tip lodges in a sinus 28, the shoulders 51 cause the distal end of tip section 38 to fold over the proximal end along a line 53 (FIG. 5) lying in the bevel plane 50 in a direction perpendicular to the plane 50. Depending upon which sinus 28 the tip 38 contacts, it may fold forward (FIG. 6) or backward (FIG. 7). In either event, the folding movement of tip 38 in the sinus 28 (FIG. 10) pushes the proximal end of tip 38 over a commisure 55 (FIG. 11) where the cannula 16 can penetrate the aortic valve 18 most easily and without risk of injury to the leaflets 30 or sinuses 28.
It is consequently essential that the material of tip 38 be soft enough to fold readily and to avoid irritating the heart's ventricular walls, yet be strong enough to fold rather than roll or telescope upon encountering an obstruction such as a sinus 28.
As the body section 34 of cannula 16 traverses the aortic valve 18 after a folding motion of tip 38, the distal end of tip 38 folds over the intake opening 46 of cannula 16 and follows the leading end of the body section 34 into the left ventricle 17. As soon as the folded portion of tip 38 has passed entirely through the aortic valve 18, its resiliency causes it to spring back to its original shape where it leaves the intake opening 46 unobstructed (FIG. 12).
It is possible that the suction of pump 10 may hold the folded distal end of tip 38 against the intake opening 46 and prevent it from returning to its original shape. To avoid this problem, auxiliary openings 48 are provided in the side of the tip section 38. The auxiliary openings 48 provide a sufficient bypass flow path to allow the inherent resilience of the tip section 38 to overcome any suction force at the intake opening 46, even if the pump 10 is operating at maximum speed.
As illustrated in FIG. 3, the auxiliary openings 48 are preferably so positioned that their axes are parallel to the bevel plane 50. In this manner, the folded portion of tip 38 (which, as pointed out above, can only fold in a direction perpendicular to the bevel plane 50) is prevented from obstructing either of the auxiliary openings 48 during passage of the tip 38 through the aortic valve 18.
It will be seen that the present invention provides an inflow cannula for intravascular pumps which is suitable for rapid, blind retrograde insertion into the left ventricle of a human heart when immediate heart assist is called for in emergencies or other situations.
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An inflow cannula for intraortic blood pumps has a curved, spring-loaded body for blind retrograde insertion through the aortic arch, and a soft, beveled foldable but resilient tip which properly positions the tip, if necessary, with respect to the aortic valve prior to retrograde insertion of the distal end of the cannula through the aortic valve. Auxiliary intake openings are provided in the side walls of the cannula adjacent its distal end to prevent suction from holding the tip in its collapsed state after insertion through the aortic valve.
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This application claims benefit of 61/728,977, filed on Nov. 21, 2012.
FIELD OF THE INVENTION
The invention relates to a process for making diastereomeric N-sulfinyl α-amino amides by reaction of chiral sulfinimines with formamides and lithium diisopropylamide. The process of the invention provides the N-sulfinyl α-amino amides in high yields and with high diastereoselectivity.
BACKGROUND OF THE INVENTION
N-sulfinyl α-amino amides can be synthesized by the Strecker process [see, e.g., S. Mabic et al., Tetrahedron 57: 8861-8866 (2001); A. Plant et al., J. Org. Chem. 73: 3714-3724 (2008); F. A. Davis et al., J. Org. Chem. 65: 8704-8708 (2000)], which requires the use of highly poisonous cyanide anion and in which the resultant alpha-amino nitrile intermediate has to be hydrolyzed under harsh conditions to yield the corresponding alpha-amino amide. Because the hydrolysis of the nitrile prepared according to the Strecker process provides only a primary amide (—CONH 2 ), the Strecker process is restricted to the synthesis of primary amides only.
The invention provides a highly diastereoselective process for making the N-sulfinyl α-amino amides of formula (I) which avoids the disadvantages of the Strecker synthesis.
It is known that the deprotonation of dialkylformamides (or dialkylthioformamides) affords carbamoyllithiums (or thiocarbamoyl lithiums). These carbamoyllithiums can then react with carbonyl electrophiles, thus allowing for the introduction of a carbamoyl group into carbonyl compounds. (See, e.g., D. Enders et al., Angew. Chem. Internat. Ed. 12:1014-1015 (1973) and B. Bánhidai et al. Angew. Chem. Internat. Ed. 12:836-836 (1973)). Reaction of carbamoyllithiums with sulfinimines as electrophiles has not been reported.
The inventors have found that carbamoyllithiums react with chiral, sterically hindered sulfinimines in a stereospecific manner to afford diastereomeric N-sulfinyl α-amino amides, which are useful as chiral building blocks for preparing pharmaceuticals.
BRIEF SUMMARY OF THE INVENTION
In its broadest embodiment (“Embodiment 1”), the invention relates to a process of making compounds of formula (I),
the process comprising reacting a compound of formula (II):
with lithium diisopropylamide to provide a first intermediate; and
reacting the first intermediate with an enantiomerically pure compound of formula (III):
to provide the compound of formula (I), wherein
X is selected from oxygen and sulfur;
R 1 and R 2 are each independently selected from C 1-6 -alkyl and phenyl;
or
R 1 and R 2 may join to form a group selected from cyclopentyl, cyclohexyl, and a 5- to 6-membered heterocycloalkyl;
R 3 is t-butyl or 2,4,6-triisopropylphenyl;
R 4 is selected from H, C 1-6 -alkyl, C 3-6 -cycloalkyl, carbocyclyl, phenyl, and 2,3-dihydrobenzo[b][1,4]dioxinyl; wherein each of the foregoing C 1-6 -alkyl, C 3-6 -cycloalkyl, carbocyclyl, phenyl and 2,3-dihydrobenzo[b][1,4]dioxinyl of said R 4 group is optionally substituted by 1 to 3 R 6 groups;
R 5 is selected from t-butyl, phenyl, phenyl-C═C(R)—, and phenyl-C≡C—; wherein each of the foregoing t-butyl, phenyl, phenyl-C═C(R)—, and phenyl-C≡C— of said R 5 group is optionally substituted by 1 to 3 R 6 groups;
or
R 4 and R 5 may join to form a group selected from cyclobutyl, cyclopentyl, cyclohexyl or dihydroindenyl, wherein each of the foregoing cyclobutyl, cyclopentyl, cyclohexyl or dihydroindenyl groups may be optionally substituted by 1 to 3 R 6 groups; and/or each of said cyclobutyl, cyclopentyl, cyclohexyl and dihydroindenyl groups may additionally be substituted by a 6-member spirocycloalkyl optionally substituted by 1 to 3 R 7 groups;
each R 6 is independently selected from halo, hydroxyl, C 1-6 -alkyl, and C 1-6 -alkyl-O—; and
each R 7 is independently selected from halo, hydroxyl, C 1-6 -alkyl, and C 1-6 -alkyl-O—.
DETAILED DESCRIPTION OF THE INVENTION
Abbreviations
DCM=dichloromethane
DMF=dimethyl formamide
LDA=lithium diisopropylamide
MTBE=methyl tert-butyl ether
THF=tetrahydrofuran
As noted above, the invention relates to methods of making compounds of formula (I) by reacting a formamide (X═O) or thioformamide (X═S) of formula (II) with LDA in the presence of a sulfinimine compound of formula (III) (hereinafter the “process of the invention”).
Embodiment 2
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in Embodiment 1, wherein X is sulfur.
Embodiment 3
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in Embodiment 1 or 2 above, wherein the compound of formula (II) is N,N-dimethylmethanethioamide.
Embodiment 4
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in Embodiment 1, wherein X is oxygen.
Embodiment 5
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in Embodiment 1 or 4, wherein the compound of formula (II) is selected from dimethyl formamide, diethyl formamide, isopropyl formamide, diphenyl formamide, pyrrolidine-1-carbaldehyde, and morpholine-4-carbaldehyde.
Embodiment 6
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in any one of Embodiments 1 to 5, wherein R 3 is t-butyl.
Embodiment 7
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in any one of Embodiments 1 to 5, wherein R 3 is 2,4,6-triisopropylphenyl.
Embodiment 8
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in any one of Embodiments 1 to 7, wherein:
R 4 is selected from H, C 1-6 -alkyl, C 3-6 -cycloalkyl, carbocyclyl, and phenyl; wherein each of the foregoing C 1-6 -alkyl, C 3-6 -cycloalkyl, carbocyclyl, and phenyl R 4 groups is optionally substituted by 1 to 3 R 6 groups; and
R 5 is selected from t-butyl, phenyl, —C═C(R)-phenyl, and —C≡C-phenyl; wherein each of the foregoing R 5 groups is optionally substituted by 1 to 3 R 6 groups.
Embodiment 9
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in any one of Embodiments 1 to 8, wherein R 4 is hydrogen.
Embodiment 10
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in any one of Embodiments 1 to 8, wherein R 4 is selected from t-butyl, trifluoromethyl, cyclopropyl, cyclohexyl, phenyl, and a group of formula 9-A,
wherein each of the foregoing R 4 group is optionally substituted by 1 to 3 R 6 groups.
Embodiment 11
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in any one of Embodiments 1 to 7, wherein R 4 and R 5 join to form a group selected from cyclobutyl, cyclopentyl, cyclohexyl or dihydroindenyl, wherein each of the foregoing cyclobutyl, cyclopentyl, cyclohexyl or dihydroindenyl groups may be optionally substituted by 1 to 3 R 6 groups; and/or each of said cyclobutyl, cyclopentyl, cyclohexyl and dihydroindenyl groups may additionally be substituted by a 6-member spirocycloalkyl optionally substituted by 1 to 3 R 7 groups.
Embodiment 12
In another embodiment, the invention relates to a process of making the compound of formula (I) as described in any one of Embodiments 1 to 7 or 11, wherein R 4 and R 5 join to form the group:
Embodiment 13
In another embodiment, the invention relates to a process of making the compound of formula (27):
the process comprising reacting N,N-diethylformamide with lithium diisopropylamide in the presence of a compound of formula (26):
to provide the compound of formula (27).
GENERAL DEFINITIONS
Halogen:
The term halogen generally denotes fluorine, chlorine, bromine and iodine.
Alkyl:
The term “C 1-6 -alkyl”, either alone or in combination with another radical denotes an acyclic, saturated, branched or linear hydrocarbon radical with 1 to n C atoms. For example the term C 1-5 -alkyl embraces the radicals H 3 C—, H 3 C—CH 2 —, H 3 C—CH 2 —CH 2 —, H 3 C—CH(CH 3 )—, H 3 C—CH 2 —CH 2 —CH 2 —, H 3 C—CH 2 —CH(CH 3 )—, H 3 C—CH(CH 3 )—CH 2 —, H 3 C—C(CH 3 ) 2 , H 3 C—CH 2 —CH 2 —CH 2 —CH 2 —, H 3 C—CH 2 —CH 2 —CH(CH 3 )—, H 3 C—CH 2 —CH(CH 3 )—CH 2 —, H 3 C—CH(CH 3 )—CH 2 —CH 2 —, H 3 C—CH 2 —C(CH 3 ) 2 —, H 3 C—C(CH 3 ) 2 —CH 2 —, H 3 C—CH(CH 3 )—CH(CH 3 )— and H 3 C—CH 2 —CH(CH 2 CH 3 )—.
Cycloalkyl:
The term “C 3-6 -cycloalkyl”, either alone or in combination with another radical denotes a cyclic, saturated, unbranched hydrocarbon radical with 3 to n C atoms. For example the term C 3-6 -cycloalkyl includes cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl.
Carbocyclyl:
The term “carbocyclyl” as used either alone or in combination with another radical, means a mono- bi- or tricyclic ring structure consisting of 3 to 14 carbon atoms. The term “carbocycle” refers to fully saturated and aromatic ring systems and partially saturated ring systems. The term “carbocycle” encompasses fused, bridged and spirocyclic systems. Nonlimiting examples of bicycloalkyls include bicylco[2.2.1]heptane, bicylco[2.2.1]heptene, bicyclo[3.2.1]octane, and bicyclo[3.2.1]octene,
Heterocyclyl:
The term “heterocyclyl” means a saturated or unsaturated mono- or polycyclic-ring systems including aromatic ring system containing one or more heteroatoms selected from N, O or S(O) r , wherein r=0, 1 or 2, consisting of 3 to 14 ring atoms wherein none of the heteroatoms is part of the aromatic ring. The term “heterocycle” is intended to include all the possible isomeric forms. Non-limiting examples of 5-6-membered heterocycloalkyl include tetrahydrofuranyl, azetidinyl, pyrrolidinyl, pyranyl, tetrahydropyranyl, dioxanyl, thiomorpholinyl, thiomorpholinyl, morpholinyl, piperidinyl, and piperazinyl.
The symbol
means the point of attachment of a group R to a moiety.
Scheme 1 below depicts the addition of formamide (and thioformamide anions) to tert-butanesulfinimines according to the process of the invention.
In the process of the invention, LDA reacts with the compound of formula (II) to form a first intermediate (carbamoyllithium) (“the lithiation step”). Typically, the first intermediate in not isolated. The first intermediate then reacts with the compound of formula (III). In one embodiment, the LDA is reacted with the compound of formula (II) in the absence of the compound of formula (III), and the resulting first intermediate is reacted with the compound of formula (III). In another embodiment, the LDA is reacted with the compound of formula (II) in the presence of the compound of formula (III).
The compounds of formula (II) are generally available from commercial sources or can be made be known methods (see e.g., Gibson, H. W. Chem. Rev. 1969, 69, 673-692).
The LDA used in the process of the invention may be obtained commercially or generated immediately prior to use by reaction of i-Pr 2 NH with a lithium alkyl, e.g., n-BuLi.
The lithiation step is carried out in anhydrous, aprotic solvent. Non-limiting examples of suitable solvents for carrying this step include toluene, THF, diethyl ether, MTBE and mixtures thereof. In a one embodiment, the lithiation step is carried out in a solvent comprising toluene.
As noted above, the lithiation step may be carried out in the absence or presence of a compound of formula (III). When absent during the lithiation step, the compound of formula (III) is subsequently reacted with the admixture comprising the carbamoyllithium. It will be understood that when the compound of formula (III) is absent during the lithiation step, the compound of formula (III) can be added to the to the reaction carbamoyllithium admixture, or the carbamoyllithium admixture can be added to the compound of formula (III), or the compound of formula (III) and the carbamoyllithium admixture can mixed together simultaneously. When the absent during the lithiation step, the compound of formula (III) may be used neat; alternatively, the compound of formula (III) may be a component of a suspension or solution comprising the anhydrous, aprotic solvents described above for the lithiation step.
The process of the invention is carried out for a time and at a temperature sufficient to provide the compound of formula (I). The process of the invention is typically carried out at a temperature from about −78° C. to about the refluxing point of the solvent. In one embodiment, the reaction of the compound of formulae (II) and LDA, optionally in the presence of the compound of formula (III), is carried out at a temperature from about −78° C. to 30° C.; more preferably from −78° C. to about 0° C.
In one embodiment, the process of the invention relates to methods of making compounds of formula (I) wherein R 4 for the compounds of formula (III) and formula (I) is hydrogen. Compounds of formula (III) where R 4 is hydrogen are referred to herein as sulfinyl aldimines. When the compound of formula (III) is a sulfinyl aldimine, the Inventors found that the selectivity is sensitive to the steric bulkiness of both the LDA and the sulfinyl aldimine. For example, the addition of DMF anion to pivaldehyde derived imine 1 gave the tert-leucine amide 2 in 92:8 selectivity (see Table 1, Example 1). When using the bulkier diisopropylformamide, the resulting amide 3 is obtained in much higher selectivity (>95:5; see Table 1, Example 2). Alternatively, the use of the more bulky 2,4,6-triisopropylphenylsulfinimine 4 in combination with DMF anion also provided a product 5 with higher selectivity (98:2; see Table 1, Example 3) than was obtained with the less sterically demanding compound 1 (92:8; see Table 1, Example 1). Likewise, the addition of diethylformamide to sulfinimine 10 gave the product in 90:10 diastereoselectivity (see Table 1, Example 6) whereas an analogous reaction with the more sterically demanding 2,4,6-triisopropylphenylsulfinimine 12 gave the product in higher selectivity (95:5; see Table 1, Example 7).
TABLE 1
Formamide anion addition to sulfinyl aldimines (where R 4 is hydrogen) a
Ex.
Sulfinimine
Formamide
Product (yield) b
dr c
1
Me 2 NCHO
92:8
2
i-Pr 2 NCHO
>95:5
3
Me 2 NCHO
98:2
4
93:7
5
Ph 2 NCHO
96:4
6
Et 2 NCHO
90:10
7
Et 2 NCHO
96:4
a Typical reaction conditions: 1 equiv sulfinimine, 3.1 equiv formamide, 3 equiv LDA, PhMe, −78° C.
b Isolated yield after chromatography on SiO 2 .
c Diastereomeric ratio determined from either HPLC or 1 H NMR of crude reaction mixture.
d TIPP = 2,4,6-triisopropylphenyl.
In another embodiment, the process of the invention relates to making compounds of formula (I) wherein R 4 for the compounds of formula (III) and formula (I) is a group other than hydrogen. Compounds of formula (III) where R 4 is a group other than hydrogen are referred to herein as sulfinyl ketimines. When the compound of formula (III) is a sulfinyl ketimine, Applicants found that the process of the invention also proceeds with high diastereoselectivity for a variety of ketimine substrates (see Table 2). Sterically demanding α-quaternary ketimines reacted to give α-quaternary β-quaternary amino amides in high diastereoselectivities (Examples 8-10 and 13 in Table 2). The enolizable ketimine 20 gave a low conversion under the standard reaction conditions, likely due to competitive enolization of the substrate on addition of LDA. However, generation of the carbamoyllithium using tert-butyllithium, and subsequent addition of ketimine 20 provided the product 21 with >90% conversion, >95:5 diastereoselectivity, and an isolated yield of 77% (Example 11, Table 2). The α,β-unsaturated ketimine 22 reacted exclusively to give the 1,2-addition product 23 with 92:8 diastereoselectivity (Example 12, Table 2). An alkynyl ketimine also reacted smoothly with N-formylpyrrolidine to provide the amino amide 25 (diastereoselectivity=94:6) (Example 13, Table 2). The reaction of cyclic ketimine 26 with LDA provided the cyclic product 27 in good yield (81%) and with high diastereoselectivity (95:5; Example 14, Table 2).
TABLE 2
Formamide anion addition to sulfinyl ketimines (where R 4 is
a group other than hydrogen) a
Ex.
Sulfinimine
Formamide
Product (yield) b
dr c
8
Et 2 NCHO
>95:5
9
Et 2 NCHO
>95:5
10
Me 2 NCHO
95:5
11
i-Pr 2 NCHO
>95:5
12
92:8
13
94:6
14
Et 2 NCHO
97:3
15
Me 2 NCHS
96:4
a Typical reaction conditions: 1 equiv sulfinimine, 3.1 equiv formamide, 3 equiv LDA, PhMe, −78° C.
b Isolated yield after chromatography on SiO 2 .
c Diastereomeric ratio determined from either HPLC or 1 H NMR of crude reaction mixture.
As noted above, the diastereomeric compounds produced by the process of the invention can serve as building blocks for further organic compounds. For example, compounds could be conveniently converted to amino ester derivatives by employing the procedure of Heimgartner and co-workers (see Scheme 2). (See also, P. Wipf et al., Helv. Chim. Acta 69: 1153-1162 (1986)). For example, deprotection of the sulfinyl group of 25 with HCl and subsequent benzoylation of the amino group gave benzamide 29. Subjection of 29 to anhydrous HCl in warm toluene effected intramolecular cyclization to an intermediate oxazolone 30, which was cleaved with methanol to give the methyl ester 31. The oxazolone formation is facilitated by the strong Thorpe-Ingold effect of the sterically demanding substrate.
EXPERIMENTAL SECTION
General Procedure
Reaction monitoring is performed by reverse phase HPLC. Reaction diastereoselectivities are determined on crude product mixtures by either reverse phase HPLC analysis or by 1 H NMR analysis.
Starting Materials:
Unless otherwise described, all reactants and reagents are obtained from commercial sources or made by known procedures. The sulfinimines are prepared by the general procedure described by Ellman and co-workers in this reference: Liu, G. et al; J. Org. Chem. 1999, 64, 1278.
Example 1
Preparation of Compound 2
Preparation of LDA solution: A flask is charged with diisopropylamine (2.30 mL, 16.37 mmol), THF (1 mL) and toluene (5 mL). The solution is cooled to about 0° C. and treated with n-BuLi (5.96 mL, 15.85 mmol, 2.67 M/hexanes) at a rate sufficient to maintain the batch at a temperature below 10° C. The resulting solution is stirred at about 0° C. for about 15 min.
A separate flask is charged with sulfinimine 1 (1.00 g, 5.28 mmol), N,N-dimethylformamide (1.23 mL, 15.85 mmol) and toluene (10 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). The LDA solution prepared above is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added and the layers are separated. The resulting organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 92:8. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 2 as a colorless oil which solidifies on standing to a colorless solid. Yield: 998 mg, 72.0%.
Example 2
Preparation of Compound 3
Preparation of LDA solution: A flask is charged with diisopropylamine (2.30 mL, 16.37 mmol), THF (1 mL) and toluene (5 mL). The solution is cooled to about 0° C. and treated with n-BuLi (5.96 mL, 15.85 mmol, 2.67 M/hexanes) at a rate sufficient to maintain the batch at a temperature below 10° C. The resulting solution is stirred at about 0° C. for about 15 min.
A separate flask is charged with sulfinimine 1 (1.00 g, 5.28 mmol), N,N-diisopropylformamide (2.38 mL, 16.37 mmol) and toluene (10 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). The LDA solution prepared above is added dropwise to the sulfinimine solution at −78° C. and stirred at about −78° C. for about 30 min Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of >95:5 (minor diastereomer not detected). The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 3 as a colorless solid. Yield: 1.25 g, 74.3%.
Example 3
Preparation of Compound 5
Preparation of LDA solution: A flask is charged with diisopropylamine (0.65 mL, 4.62 mmol), THF (0.5 mL) and toluene (2.5 mL) and cooled to about 0° C. The solution is treated with n-BuLi (1.67 mL, 4.47 mmol, 2.67 M/hexanes) at a rate sufficient to maintain the batch at a temperature below 10° C. The resulting solution is stirred at about 0° C. for about 15 min.
A separate flask is charged with sulfinimine 4 (500 mg, 1.49 mmol), N,N-dimethylformamide (0.36 mL, 4.62 mmol) and toluene (5 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). The LDA solution prepared above is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (10 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (20 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. HPLC analysis of the crude product shows a diastereomeric ratio of 98:2. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 5 as a colorless oil. Yield: 507 mg, 83.3%.
Example 4
Preparation of Compound 7
Preparation of LDA solution: A flask is charged with diisopropylamine (0.94 mL, 6.67 mmol), THF (0.5 mL) and toluene (2.5 mL). The solution is cooled to about 0° C. and treated with n-BuLi (2.43 mL, 6.46 mmol, 2.67 M/hexanes) at a rate sufficient to maintain the batch at a temperature below 10° C. The resulting solution is stirred at about 0° C. for about 15 min.
A separate flask is charged with sulfinimine 6 (500 mg, 2.15 mmol), N-formylmorpholine (0.67 mL, 6.67 mmol) and toluene (5 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). The LDA solution prepared above is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (10 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase are dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 93:7. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 7 as a colorless oil. Yield: 571 mg, 76.4%.
Example 5
Preparation of Compound 9
A flask is charged with sulfinimine 8 (500 mg, 1.74 mmol), N,N-diphenylformamide (684 mg, 3.47 mmol) and THF (5 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). Commercial LDA solution (1.74 mL, 3.47 mmol, 2.0 M/THF/heptane/ethylbenzene) is added dropwise rate to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (10 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 96:4. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 9 as a white solid. Yield: 714 mg, 84.8%.
Example 6
Preparation of Compound 11
A flask is charged with sulfinimine 10 (500 mg, 1.87 mmol), N,N-diethylformamide (0.644, 5.80 mmol) and toluene (5 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). Commercial LDA solution (2.90 mL, 5.80 mmol, 2.0 M/THF/heptane/ethylbenzene) is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (10 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 90:10. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 11 as a colorless oil. Yield: 570 mg, 82.7%.
Example 7
Preparation of Compound 13
Preparation of LDA solution: A flask is charged with diisopropylamine (1.20 mL, 8.58 mmol), THF (1 mL) and toluene (5 mL). The solution is cooled to about 0° C. The solution is treated with n-BuLi (3.11 mL, 8.30 mmol, 2.67 M/hexanes) at a rate sufficient to maintain the batch at a temperature below 10° C. The resulting solution is stirred at about 0° C. for about 15 min.
A separate flask is charged with sulfinimine 12 (1.00 g, 2.77 mmol), N,N-diethylformamide (0.96 mL, 8.58 mmol) and toluene (10 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). The LDA solution prepared above is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 95:5. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 13 as a colorless oil which solidified on standing to a colorless solid. Yield: 1.04 g, 81.3%.
Example 8
Preparation of Compound 15
Preparation of LDA solution: A flask is charged with diisopropylamine (2.67 mL, 19.03 mmol), THF (1 mL) and toluene (5 mL). The solution is cooled to about 0° C. and treated with n-BuLi (7.08 mL, 18.84 mmol, 2.67 M/hexanes) at a rate sufficient to maintain the batch at a temperature below 10° C. The resulting solution is stirred at about 0° C. for about 15 min.
A separate flask is charged with sulfinimine 14 (500 mg, 1.88 mmol), N,N-dimethylformamide (1.47 mL, 19.03 mmol) and toluene (5 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). The LDA solution prepared above is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of >95:5 (minor diastereomer not detected). The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 15 as a white solid. Yield: 497 mg, 77.9%.
Example 9
Preparation of Compound 17
A flask is charged with sulfinimine 16 (500 mg, 1.26 mmol), N,N-diethylformamide (1.30 mL, 11.70 mmol) and toluene (5 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). Commercial LDA solution (5.66 mL, 11.32 mmol, 2.0 M/THF/heptane/ethylbenzene) is charged dropwise to the sulfinimine solution at a rate sufficient to maintain the temperature at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of >95:5 (minor diastereomer not detected). The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 17 as a white solid. Yield: 472 mg, 75.2%.
Example 10
Preparation of Compound 19
A flask is charged with sulfinimine 18 (500 mg, 1.46 mmol), N,N-dimethylformamide (0.35 mL, 4.52 mmol) and toluene (5 mL) and cooled in a dry ice/acetone bath (−78° C.). Commercial LDA solution (2.12 mL, 4.38 mmol, 2.0 M/THF/heptane/ethylbenzene) is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 95:5. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 19 as a white solid. Yield: 426 mg, 70.2%.
Example 11
Preparation of Compound 21
A flask is charged with N,N-diisopropylformamide (0.58 mL, 4.01 mmol), THF (20 mL), Et 2 O (20 mL), and pentane (5 mL) and cooled in a dry ice/acetone bath (−78° C.). Tert-butyllithium solution (2.60 mL, 4.41 mmol, 1.7 M/pentane) is added dropwise to the solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. A solution of sulfinimine 20 (500 mg, 2.01 mmol) in THF (5 mL) is added dropwise at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of >95:5 (minor diastereomer not detected). The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 21 as a white solid. Yield: 584 mg, 76.9%.
Example 12
Preparation of Compound 23
Preparation of LDA solution: A flask is charged with diisopropylamine (0.70 mL, 4.98 mmol), THF (0.5 mL) and toluene (5 mL) and cooled to about 0° C. The solution is treated with n-BuLi (1.81 mL, 4.82 mmol, 2.67 M/hexanes) at a rate sufficient to maintain the batch at a temperature below 10° C. The resulting solution is stirred at about 0° C. for about 15 min.
A separate flask is charged with sulfinimine 22 (500 mg, 1.61 mmol), N-formylmorpholine (0.50 mL, 4.98 mmol) and toluene (5 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). The LDA solution prepared above is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 92:8. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 23 as a white solid. Yield: 460 mg, 67.2%.
Example 13
Preparation of Compound 25
A flask is charged with sulfinimine 24 (500 mg, 1.73 mmol), N-formylpyrrolidine (1.00 mL, 10.54 mmol) and toluene (5 mL), and the mixture is cooled in a dry ice/acetone bath (−78° C.). Commercial LDA solution (5.18 mL, 10.37 mmol, 2.0 M/THF/heptane/ethylbenzene) is added dropwise to the sulfinimine solution at −78° C. The reaction mixture is stirred at about −78° C. for about 30 min. Water (15 mL) is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate (30 mL) is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 94:6. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 25 as a light brown oil. Yield: 491 mg, 73.1%.
Example 14
Preparation of Compound 27
A. Preparation of Compound 26:
Step 1: Synthesis of Intermediate 29a
To a mixture of 6-bromo-indan-1-one (100.00 g, 473.8 mmol) in anhydrous THF (1 L) at 0° C. was added t-BuOK (58.5 g, 521.2 mmol, 1.1 eq), 2 min later the mixture was warmed up to room temperature and was stirred for another 10 min before methyl methacrylate (49.8 g, 53.2 mL, 497.5 mmol, 1.05 eq) was added in one portion. After 2 h, methyl acrylate (49.0 g, 51.2 mL, 568.6 mmol, 1.2 eq) was added to the reaction mixture. After 3 h at room temperature, MeI (101 g, 44.3 mL, 710.7 mmol, 1.5 eq) was added to the reaction mixture, and it was stirred for 16 hours. H 2 O (1 L) was added followed by LiOH.H 2 O (79.5 g, 1895.2 mmol, 4.0 eq), the mixture was stirred for 28 h at room temperature. THF was removed under reduced pressure. The residue was diluted with H 2 O (1 L) and filtered, washed with H 2 O until the filtrate was neutral. The product was washed with to afford 50 g of intermediate 29a.
Step 2: Synthesis of Intermediate 29b
A mixture of FeCl 3 (6.0 g, 37.0 mmol) with toluene (60 mL) was cooled to 0° C. A mixture of compound 29a (11.9 g, 37.0 mmol) in THF (48 mL) was then added to the mixture. The mixture was stirred for 5 min at 0° C. and then cooled to −10° C. A solution of t-BuNH 2 —BH 3 (3.5 g, 40.7 mmol) in THF (12 mL) was added dropwise to the reaction mixture at −10° C. The reaction mixture was stirred at about −10° C. for 30 min, quenched with 6N aq HCl solution (10 mL), stirred at about 0° C. for 30 min, and then allowed to warm to room temperature. The mixture was concentrated to remove THF, and toluene (60 mL) was added. The aqueous layer was removed, and the organic phase was washed with water (3×60 mL). The organic phase was concentrated to ½ volume, heated to 50° C. to obtain a solution, and then cooled to 0° C. over 1 h and held at 0° C. for 1 h. The solid was filtered and washed with cold (0° C.) toluene (12 mL), and dried under vacuum to give compound 29b (9.93 g, 83%). LC-MS: tR=2.36 min, MS (ESI) m/z 323.0/325.0 [M+H] + .
Step 3. Synthesis of Intermediate 29c
To a mixture of compound 29b (20.0 g, 61.9 mmol) with DMF (200 mL) was added NaH (5.0 g, 123.8 mmol, 2.0 eq) at 0° C. Then it was stirred for 15 min at 0° C. and MeI (17.6 g, 123.8 mmol, 2.0 eq) was added at 0° C. Then it was warmed to room temperature and stirred for 1.5 h at room temperature. The mixture was quenched with H 2 O and extracted with EtOAc. The combined organic phases were washed with H 2 O and brine, dried, concentrated to afford crude product, which was purified by column on silica gel (eluent:petroleum ether:ethyl acetate from 100/1 to 5/1) to afford intermediate 29c (20 g, 96.2%).
Step 4. Synthesis of Compound 26
The mixture of compound 34 (20.0 g, 59.3 mmol) and titanium (IV) ethoxide (108.2 g, 474.4 mmol) in dry THF (200 ml) was stirred at room temperature for 1 hour. N-tert-butylsulfinamide (29 g, 237.2 mmol) was added. The resulting mixture was stirred at 80° C. under N 2 atmosphere overnight. The reaction mixture was then cooled and water (400 ml) was added. The mixture was filtered and the aqueous layer was extracted with ethyl acetate (3×400 mL). The separated organic phase was dried and concentrated under reduced pressure to give crude product. The residue was purified by column chromatography on silica gel (petroleum ether: ethyl acetate=20:1) to give intermediate 35 (18.4 g, 70.5%).
B. Preparation of Compound 27
A solution of sulfinimine 26 (10.0 g, 22.7 mmol) and N,N-diethylformamide (7.0 mL, 62.8 mmol) in toluene (80 mL) is cooled to −10° C. LDA solution (30.4 mL, 60.8 mmol, 2.0M in THF/heptane/ethylbenzene) is then added dropwise to the reaction mixture at −10° C. The mixture is stirred for 30 min at −10° C., quenched with water (40 mL) and then allowed to warm to room temperature. The aqueous layer is removed, and the organic phase is washed with water (40 mL). The organic phase is concentrated under vacuum at 50-60° C. to the minimum volume and treated with heptane (80 mL). The mixture is again concentrated under vacuum at 50-60° C. to the minimum volume and treated with heptane (60 mL). The mixture is allowed to cool to room temperature, further cooled to about 0° C., and held at 0° C. for about 1 hour. The solid is filtered, washed with cold (0° C.) heptane (10 mL), and dried under vacuum to (1r,1′R,3R,4R,5S)-6′-bromo-1′-((S)-1,1-dimethylethylsulfinamido)-N,N-diethyl-4-methoxy-3,5-dimethyl-1′,3′-dihydrospiro[cyclohexane-1,2′-indene]-1′-carboxamide give compound 27 (8.50 g, 76%, 98.2 wt. % purity, >99.5% diastereomeric purity) as a white solid.
Example 15
Preparation of Compound 28
A solution of sulfinimine 26 (2.0 g, 4.54 mmol and N,N-dimethylthioformamide (0.77 mL, 9.08 mmol) in toluene (12 mL) is cooled to −10° C. LDA solution (4.54 mL, 9.08 mmol, 2.0M in THF/heptane/ethylbenzene) is then added dropwise to the reaction mixture at −10° C. Water is added, and the reaction mixture is warmed to about 25° C. Ethyl acetate is added, and the layers are separated. The organic phase is dried over sodium sulfate, filtered, and concentrated by distillation at reduced pressure to give the crude product. 1 H NMR analysis of the crude product shows a diastereomeric ratio of 96:4. The crude product is purified by flash column chromatography on SiO 2 using hexanes/ethyl acetate as eluent to give the diastereomerically pure product 28 as a light brown oil. Yield: 2.02 g, 84.0%.
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Disclosed is a process for making diastereomeric N-sulfinyl α-amino amides by reaction of chiral sulfinimines with formamides and lithium diisopropylamide. The process of the invention provides the N-sulfinyl α-amino amides in high yields and with high diastereoselectivity.
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BACKGROUND OF THE INVENTION
The present invention relates to screw hole plugs, and more particularly to a plug adapted for installation within a limited depth screw hole through a nonplanar surface.
Many structural elements, such as moldings, have screw holes. Typically, the screw holes are formed before the screws are inserted and include a countersink creating a shoulder. The head of a screw seats against the shoulder and is recessed below the molding surface. Such screw holes are unsightly and aesthetically unattractive. The screw holes interrupt the smooth flow of the exposed surface.
One prior approach to reducing the unsightliness of screw holes is to make the countersunk portion of the screw hole as shallow as possible. However, these reduced depth screw holes have defied prior attempts to create a screw hole plug suitable for installation therein.
SUMMARY OF THE INVENTION
The aforementioned problems are overcome by the present invention wherein a screw hole plug is provided which friction fits within the countersink and frictionally grips the screw head located within the countersink. The plug includes a circumferential wall fitting within the screw hole and over the screw head. The plug further preferably includes a top having a profile matching the exposed surface of the structural element. Consequently, the installed screw hole plug is flush with the surface.
The present invention provides a simple yet effective screw hole cap for virtually any type of countersunk screw head. Especially when preferably made by injection molding, the plug is inexpensive and readily suited to mass manufacture.
These and other objects, advantages, and features of the invention will be more readily understood and appreciated by reference to the detailed description of the preferred embodiment and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary exploded perspective view of a molding assembly including the screw hole plug of the present invention;
FIG. 2 is a sectional view taken alone line II--II through the assembled components of FIG. 1;
FIG. 3 is a top plan view of the screw hole plug;
FIG. 4 is a side elevational view of the screw hole plug;
FIG. 5 is a front elevational view of the screw hole plug; and
FIG. 6 is a fragmentary perspective view similar to FIG. 1, but showing the components assembled.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The screw hole plug of the present invention is illustrated in the drawings and generally designated 10. As perhaps best illustrated in FIG. 2, the screw hole plug is friction fitted into the countersink 12 in a molding 14 to also frictionally grip the head 16 of the screw 18. The resultant assembly is illustrated in FIG. 6 wherein it is readily seen that the screw hole plug and molding 14 provide a generally continuous exposed surface.
The molding 14 in which the screw hole plug 10 is mounted is generally well known to those having ordinary skill in the art. Such moldings are used by the assignee of the present application to provide framing elements for door lights. These moldings are injection molded of high heat, high impact grade polystyrene. The molding 14 has a generally uniform wall thickness as seen in FIGS. 1 and 6. The molding 14 includes an exposed surface 20 having a curvilinear or other nonplanar configuration or shape in cross-section. The shape of the exposed surface is selected for aesthetic reasons and will vary from molding to molding.
As seen in FIG. 2, the molding 14 includes a plurality of screw bosses 24 on its underside 22. Only one such screw boss is illustrated in FIG. 2, but the bosses are provided at spaced locations. The screw boss defines a generally centrally located screw hole 26. A similar screw boss 24' of a mating molding piece defines a screw hole 26' of smaller diameter to secure the screw as will be described. As seen in FIGS. 1 and 2, the screw hole is generally aligned with the screw boss 24 and extends through the exposed surface 20 of the molding 14. The upper portion of the screw hole is a countersink 12 having a diameter larger than the remainder of the screw hole 26. The juncture of the countersink 12 and the screw hole 26 creates a shoulder 28 against which the screw head seats as will be described.
A conventional pan head screw 18 extends through the screw hole 26 to interconnect the two moldings. The threaded shaft of the screw 18 is smaller in diameter than the screw hole 26 so that the threads do not grip the screw boss 24. However, the diameter of opposing screw hole 26' is selected so that the screw 18 will bite into the opposing screw boss 24' to intersecure the two molding pieces. The head 16 of the screw 18 seats on the shoulder 28 so that the head is located within the countersink 12 below the exposed surface 20. The molding 14 and the screw 18 are generally well known to those having skill in the doorlight art.
The screw hole cap 10 is illustrated in greatest detail in FIGS. 3-5. Generally speaking, the plug has a cylindrical side wall 30 and a curvilinear top wall 32. The cylindrical side wall 30 includes a lower edge 34 defining a plane generally perpendicular to the axis of the cylindrical side wall. The outer surface of the side wall 30 defines a circular cylinder having a diameter only slightly larger than the diameter of the countersink 12. Consequently the side wall 30 friction fits within the countersink 12. The inner surface of the side wall 30 is slightly tapered having its largest diameter at the opening to the cavity 40. This largest diameter is slightly smaller than the diameter of the screw head 16 so that the side wall frictionally grips the screw head. The side wall 30 also includes an upper edge 36 having a high portion 36a and a low portion 36b.
The top wall 32 is curvilinear in side elevational profile as illustrated in FIG. 4. The curvilinear shape of the side wall 32 matches the curvilinear shape or configuration of the exposed molding surface 20. The top wall 32 is connected to the entire upper peripheral edge 36 of the cylindrical side wall 30. The side wall 30 and top wall 32 therefore together define a cavity 40 receiving the screw head 16.
The plug or cap 10 is preferably injection molded. In the presently preferred embodiment, the cap is molded of high heat, high impact grade polystyrene resin such as that sold as No. 825 by Fina Oil & Chemical Company of Dallas, Tex. (White Colorant #71-1170-1 by Ferro Corporation of Schaumburg, Ill.). The preferred wall thickness is 0.040 inch. Graining, such as to similate oak wood, or other surface texture can be molded into the top wall 32 as desired to match any graining or surface texture provided in the molding surface 20.
In use, the screw hole plug 10 is inserted after the screw 18 is installed to intersecure the molding pieces. Specifically, the screw 18 is inserted and tightened as desired so that the screw head 16 seats against the shoulder 28 to provide the desired intersecuring force between the molding pieces. The screw hole plug 10 is then inserted into the countersink 12 of the screw hole. The angular orientation of the cap 10 is selected so that the nonplanar top wall 32 of the plug 10 is aligned with the nonplanar surface 20 of the molding 14. The outer surface of the side wall 30 frictionally fits within the countersink 12 to at least partially secure the cap in position. The inside surface of the side wall 30 fits over and frictionally grips the head of the screw to further retain the cap 10 in position. Consequently, the cap will be operative in a screw hole or countersink of only limited depth.
FIG. 6 shows the molding 14 with the screw cap 10 properly installed. As can be seen, the screw hole plug 10 provides a continuous surface with the exposed surface 20 of the molding to provide an aesthetically pleasing appearance.
It should be understood that the above description is that of a preferred embodiment of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as set forth in the appended claims, which are to be interpreted in accordance with the principles of patent law, including the doctrine of equivalents.
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The specification discloses a one-piece injection-molded screw hole plug fitting over a screw head to aesthetically close a screw hole. The element defining the screw hole and the top of the screw hole plug have nonplanar, but mating, contours so that the molding and plug define a generally continuous surface. Preferably, the screw hole plug friction fits within the screw hole and over the screw head to retain the plug in position.
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FIELD OF THE INVENTION
[0001] The invention disclosed broadly relates to the field of information handling systems and more particularly relates to the field of representing Extensible Markup Language (XML) documents in memory.
BACKGROUND OF THE INVENTION
[0002] “Extensible Markup Language” (XML) is a textual notation for a class of data objects called “XML Documents” and partially describes a class of computer programs processing them. A characteristic of XML documents is that they use a hierarchical structure to organize information within the documents. This hierarchical structure may be represented using a rooted-tree data structure with nodes representing the “elements” of the XML document. Element nodes may have a tag name, may be associated with named attributes, and may have relationships to other nodes in the tree, where such relationships may refer to “parent” and “child” nodes. In addition, element nodes may contain data in various forms (specifically text, comments, and special “processing instructions”).
[0000] XML Document Trees
[0003] An XML document can be represented as a labeled tree whose nodes represent the structural components of the document—elements, text, attributes, comments, and processing instructions. Element and attribute nodes have labels derived from the corresponding tags in the document and there may be more than one node in the document with the same label. Parent-child edges in the tree represent the inclusion of the child component in its parent element, where the scope of an element is bounded by its start and end tags. The tree corresponding to an XML document is rooted at a virtual element, called the root, which represents the document itself. Hereinafter, XML documents will be discussed in terms of their tree representations. One can define an arbitrary order on the nodes of a tree. One such order might be based on a left-to-right depth-first traversal of the tree, which, for a tree representation of an XML document, corresponds to the document order. The memory footprint of an XML document can be large. XML processors may not be able to handle large documents due to the memory requirement of storing the entire document. As a result, in processing XML, reducing the memory overhead of an XML document is of great importance.
[0000] XPath
[0004] “XML Path Language” (XPath) is a query language for creating an expression that selects nodes of data from an XML document. XPath is used to address XML data using path notation to navigate through the hierarchical structure of an XML document. XPath queries allow applications to determine if a given node matches a pattern, including patterns involving its location in the XML document hierarchy.
[0005] XPath has been widely accepted in many environments, especially in database environments. Given the importance of XPath as a mechanism for querying and navigating data, it is important that the evaluation of XPath expressions on XML documents be as efficient as possible.
[0000] XML Processing
[0006] In traditional XML processing, a tree representation of an XML document that is to be processed is built in memory. When the document is large, this construction of the tree representation, for example, as an instance of the familiar Document Object Model (DOM), may be prohibitively expensive in both time and memory. For large documents, XML processing may fail due to the large memory requirements of the document. In main-memory XML processors, one of the primary sources of overhead is the cost of constructing and manipulating main-memory representations of XML documents.
[0007] Alternatives to parsing the entire document include solutions known to those of skill in the art, such as using a Simple API for XML (SAX). SAX is an example of an event-based object model for parsing XML documents. Many applications, however, are difficult to develop applications using SAX's event-based framework. The explicit construction of an in-memory tree using a framework such as DOM can simplify application development, but can have high performance overhead. Even when an application uses only a small portion of the document, the application must pay the cost of constructing the entire tree in memory. It is, therefore, important to have a mechanism by which an application developer can write an application assuming a framework such as DOM, but construct the tree representation of an XML document lazily in memory in response to accesses by the application. Rather than constructing the tree entirely in memory, the mechanism would create a “virtual” DOM where only small portions of the XML document are instantiated in memory. When a program accesses portions that have not been instantiated, the underlying mechanism would instantiate them dynamically in response to the requests. In this manner, applications can be developed easily using a framework such as DOM, while the implementation is efficient because only relevant portions of XML documents are actually instantiated in memory.
[0008] In many circumstances, an XML document is read in, processed and then sent to another destination. The conversion of an in-memory representation of an XML document into a series of bytes that can be transmitted to another process is called serialization. Serialization can be an expensive operation—the entire tree corresponding to a document must be navigated and emitted as a series of bytes. Because the serialization of XML documents is a common operation, it is important to ensure that it performs as well as possible.
SUMMARY OF THE INVENTION
[0009] Briefly, according to an embodiment of the invention, a method, information processing system, and computer readable medium for improved representation of hierarchical documents, particularly a document encoded in Extended Markup Language (XML), where a hierarchical document and stored into an addressable data structure such as a byte array, and portions of the documents are instantiated as a tree from the byte array in response to requests by an application or program.
[0010] An XML document is read and parsed into a byte array, which is generally a more concise representation of data than a tree representation. When requests for portions of a tree, for example using XPath queries, are received by an application, the system verifies whether the portion of the tree corresponding to the tree has already been expanded. If not, the byte array is then parsed and only those nodes relevant to the request of query are expanded into a tree representation. The system continues to process requests for navigation, expanding elements as necessary, assuring that each navigation produces an identical result as evaluating the request against the original hierarchical document.
[0011] When a document is serialized, the system uses the byte array to efficiently emit the series of bytes corresponding to the document. If portions of the document are modified, the unmodified portions are emitted using the byte array. Modified portions are emitted using traditional serialization mechanisms—traversing the modified portions and emitting the bytes corresponding to them.
[0012] The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and also the advantages of the invention, will be apparent from the following detailed description taken in conjunction with the accompanying drawings. Additionally, the left-most digit of a reference number identifies the drawing in which the reference number first appears.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a tree representation of an XML document in one embodiment of the present invention.
[0014] FIG. 2 illustrates a possible system architecture for a system embodying the present invention.
[0015] FIG. 3 illustrates a representation of the XML document of FIG. 1 showing materialized and inflatable nodes, in one embodiment of the present invention.
[0016] FIG. 4 is a high level block diagram showing an information processing system useful for implementing an embodiment of the present invention.
DETAILED DESCRIPTION
[0017] We describe a method, computer readable medium, and information processing system for querying of hierarchical documents, such as documents encoded in Extended Markup Language (XML). We use a compact representation for XML documents that we call an inflatable tree. The basis of this representation is the observation that the binary representation of XML as a sequence of bytes can be five times more concise than the DOM (Document Object Model) or XQuery data model representation of XML. The representation of the present invention initially stores the bytes corresponding to the XML document in a byte array (“inflatable tree”). It dynamically builds a projection of the XML document in response to XPath expressions issued by a query processor. The inflatable tree representation enables efficient serialization of results to clients since the portions of the results that correspond to parts of the input document can be serialized directly from the byte array.
[0018] The inflatable tree representation substantially reduces the construction and serialization time in query processing. For certain queries that involve traversals of the entire tree (such as the descendant axes), query evaluation time will be improved as well. Furthermore, the inflatable tree representation allows a query processor to handle larger documents than it might otherwise (approximately, twenty-five (25) times the corresponding DOM representation).
System Architecture
[0019] The architecture of a system 200 using an embodiment of the invention is depicted in FIG. 2 . A client 210 loads a document 220 (or set of documents) by issuing a request to the Document Manager 230 . A reference to the root of the inflatable tree representation 240 of the document 220 is returned to the client. The client 210 then processes the inflatable tree representation 240 , and may issue further requests (for example, XPath queries) to the Document Manager 230 . In response, the Document Manager 230 may expand portions of the inflatable tree representation 240 to return nodes in the tree corresponding to the request by the client. Eventually, the client may request a serialization 260 of the XML document into a byte form so that it may send the XML document to another processor.
[0020] The following describes the tree representation of the present invention and how the client interacts with it in greater detail. For simplicity, the description focuses on XML elements, though one of ordinary skill in the art will be aware that the implementation can also handle the other XML nodes, such as attribute nodes.
Inflatable Trees
[0021] Our representation of XML documents, an inflatable tree, is based on the observation that the binary representation of an XML document (as a sequence of bytes) can be 4-5 times more concise than constructing an XQuery or DOM (Document Object Model) model instance of the document. Given a reference to an XML document, we store the sequence of bytes corresponding to the XML document in an array of bytes in memory. Our representation of the XML document in memory consists of two sorts of nodes: materialized nodes and inflatable nodes. A materialized node corresponds to an element in the document and contains all information relevant to the element, such as its tag and its unique identifier. An inflatable node represents an unexpanded portion of the XML document; it contains a pair of offsets into the byte array representation of the document corresponding to the start and end of the unexpanded portion. FIG. 3 ( a ) depicts the inflatable tree representation of the XML document tree in FIG. 1 . The highlighted nodes in FIG. 1 are materialized nodes ( 100 , 110 , 120 , 130 , 140 , 150 , 160 , 170 , 180 , and 190 ) in FIG. 3 ( a ). The nodes in FIG. 3 that have a dashed border ( 300 , 310 , 320 , 330 ) are inflatable nodes. Inflatable nodes contain start and end offsets into the binary array of bytes of the XML document. We will also store offsets with materialized nodes corresponding to the start and end offsets of the subtree rooted at that materialized element. The start offset of an element can be used as the unique identifier for that element.
Construction of XML
[0022] All new XML elements that the client 210 wishes to construct are constructed as materialized nodes. When, however, construction refers to subtrees from input documents, the Document Manager 230 may construct an inflatable node with the appropriate offsets. For example, consider the evaluation of the following XQuery on the document of FIG. 1 .
Pubs> for $a in //Publisher return $a </Pubs>
[0023] FIG. 3 ( b ) shows the result of constructing the result of this XQuery expression. The constructed tree contains inflatable nodes 340 and 350 that refer to the appropriate portions of the input document.
[0024] An update to an inflatable tree is treated similarly. The new update tree is stored as in materialized form.
Serialization of Results
[0025] Since the byte array representation of the input XML documents is retained in memory, portions of the results that are derived from the input document can be serialized directly from the byte array. This direct serialization can be substantially more efficient than explicit traversal of a tree to perform serialization. For example, in FIG. 3 ( b ), the inflatable nodes 340 and 350 corresponding to the Pubs elements can be serialized directly from input document byte array 360 .
Deflation
[0026] At certain points, either the client or the system can recognize that an inflated portion of the inflatable tree can be deflated, that is, the tree representation can be converted back into a byte array representation. The system will process the corresponding portions of the inflatable tree and emit the bytes into a binary array and replace the appropriate materialized nodes with inflatable nodes. In this way, the system can control the amount of memory used by an inflatable tree.
Implementing Embodiments
[0027] The system 200 may be implemented using a custom parser to generate the start and end element events corresponding to a depth-first traversal of a document. A key characteristic of the parser is the ability to support controlled parsing over a byte array—we can specify the start and end offsets of the byte array that the parser should use as the basis for parsing. This property is essential for the parsing of subtrees corresponding to inflatable nodes. Another feature of the parser is that at element event handlers, it provides offset information rather than materializing data as SAX does. For example, rather than constructing a string representation of the element tag's name, it returns an offset into the array and a length.
[0028] An embodiment of the present invention is implemented in Java, using the Xerces DOM representation as the underlying representation for the inflatable tree. Materialized nodes are represented as normal DOM nodes. Inflatable nodes have a special tag “_INFLATABLE_” and they contain two attributes indicating the start and end offsets in the byte representation of the document. The ability to use of DOM as our underlying representation is a key advantage—we are able to run DOM-based XPath parsers as is on our inflatable trees.
[0029] The presence of the byte array corresponding to the document allows for a drastic reduction in the size of the in memory representation, which in turn, reduces construction time. Furthermore, the cost of serialization reduces by a factor of four. The serialization of XML from a data model instance can be slow since the serializer must traverse the entire DOM instance and output the appropriate XML constructs. The byte array allows the serialization mechanism of the present invention to avoid this cost.
Computer Implementation
[0030] Embodiments of the invention can be realized in hardware, software, or a combination of hardware and software. A system according to a preferred embodiment of the present invention can be realized in a centralized fashion in one computer system, or in a distributed fashion where different elements are spread across several interconnected computer systems. Any kind of computer system—or other apparatus adapted for carrying out the methods described herein—is suited. A typical combination of hardware and software could be a general-purpose computer system with a computer program that, when being loaded and executed, controls the computer system such that it carries out the methods described herein.
[0031] An embodiment of the present invention can also be embedded in a computer program product, which comprises all the features enabling the implementation of the methods described herein, and which—when loaded in a computer system—is able to carry out these methods. Computer program means or computer program in the present context mean any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following: a) conversion to another language, code or, notation; and b) reproduction in a different material form.
[0032] A computer system may include, inter alia, one or more computers and at least a computer readable medium, allowing a computer system, to read data, instructions, messages or message packets, and other computer readable information from the computer readable medium. The computer readable medium may include non-volatile memory, such as ROM, Flash memory, Disk drive memory, CD-ROM, and other permanent storage. Additionally, a computer readable medium may include, for example, volatile storage such as RAM, buffers, cache memory, and network circuits. Furthermore, the computer readable medium may comprise computer readable information in a transitory state medium such as a network link and/or a network interface, including a wired network or a wireless network, that allow a computer system to read such computer readable information.
[0033] FIG. 4 is a high level block diagram showing an information processing system useful for implementing one embodiment of the present invention. The computer system includes one or more processors, such as processor 404 . The processor 404 is connected to a communication infrastructure 402 (e.g., a communications bus, cross-over bar, or network). Various software embodiments are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person of ordinary skill in the relevant art(s) how to implement the invention using other computer systems and/or computer architectures.
[0034] The computer system can include a display interface 408 that forwards graphics, text, and other data from the communication infrastructure 402 (or from a frame buffer not shown) for display on the display unit 410 . The computer system also includes a main memory 406 , preferably random access memory (RAM), and may also include a secondary memory 412 . The secondary memory 412 may include, for example, a hard disk drive 414 and/or a removable storage drive 416 , representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 416 reads from and/or writes to a removable storage unit 418 in a manner well known to those having ordinary skill in the art. Removable storage unit 418 , represents a floppy disk, a compact disc, magnetic tape, optical disk, etc. which is read by and written to by removable storage drive 416 . As will be appreciated, the removable storage unit 418 includes a computer readable medium having stored therein computer software and/or data.
[0035] In alternative embodiments, the secondary memory 412 may include other similar devices for allowing computer programs or other instructions to be loaded into the computer system. Such devices may include, for example, a removable storage unit 422 and an interface 420 . Examples of such may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units 422 and interfaces 420 which allow software and data to be transferred from the removable storage unit 422 to the computer system.
[0036] The computer system may also include a communications interface 424 . Communications interface 424 allows software and data to be transferred between the computer system and external devices. Examples of communications interface 424 may include a modem, a network interface (such as an Ethernet card), a communications port, a PCMCIA slot and card, etc. Software and data transferred via communications interface 424 are in the form of signals which may be, for example, electronic, electromagnetic, optical, or other signals capable of being received by communications interface 424 . These signals are provided to communications interface 424 via a communications path (i.e., channel) 426 . This channel 426 carries signals and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, an RF link, and/or other communications channels.
[0037] In this document, the terms “computer program medium,” “computer usable medium,” and “computer readable medium” are used to generally refer to media such as main memory 406 and secondary memory 412 , removable storage media 418 , a hard disk installed in hard disk drive 414 , and signals. These computer program products are means for providing software to the computer system. The computer readable medium allows the computer system to read data, instructions, messages or message packets, and other computer readable information from the computer readable medium.
[0038] Computer programs (also called computer control logic) are stored in main memory 406 and/or secondary memory 412 . Computer programs may also be received via communications interface 424 . Such computer programs, when executed, enable the computer system to perform the features of the present invention as discussed herein. In particular, the computer programs, when executed, enable the processor 404 to perform the features of the computer system. Accordingly, such computer programs represent controllers of the computer system.
[0039] What has been shown and discussed is a highly-simplified depiction of a programmable computer apparatus. Those skilled in the art will appreciate that other low-level components and connections are required in any practical application of a computer apparatus.
[0040] Therefore, while there has been described what is presently considered to be the preferred embodiment, it will be understood by those skilled in the art that other modifications can be made within the spirit of the invention.
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A method, information processing system, and computer readable medium for improved representation of hierarchical documents, particularly a document encoded in Extended Markup Language (XML). The method loads a hierarchical document and stores into an addressable data structure such as a byte array. It then expands the addressable data structure lazily in response to navigations requested by a client. Nodes requested by the client are materialized, that is, they are created in memory, whereas other nodes are left unmaterialized in byte form. The method reduces the memory footprint of an XML document, as well as, improves query evaluation time and serialization time.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application relates to and claims priority from U.S. Provisional Application No. 60/727,122, filed Oct. 14, 2005, incorporated herein by reference.
TECHNICAL FIELD
The present application relates to microemulsions which are effective for incorporating water-insoluble components into aqueous-based food and beverage compositions or water-soluble components into lipid-based food compositions.
BACKGROUND OF THE INVENTION
The formulation of food and beverage products, particularly aqueous-based food and beverage products, can be difficult. For example, it is frequently necessary to incorporate water immiscible components, such as colors, flavors, nutrients, nutraceuticals, therapeutic agents, or antioxidants, into compositions which are primarily aqueous based. The difficulty of this task is increased by the fact that the compositions need to be formulated such that they are esthetically pleasing to the consumer. For example, it is frequently necessary to incorporate a water-insoluble material into an aqueous beverage while still maintaining the optical clarity of the beverage. These compositions also need to exhibit long-term shelf stability under typical food and beverage shipping, storage and use conditions.
One way that the industry has attempted to satisfy these conflicting requirements is to incorporate the water immiscible materials using microemulsions. A microemulsion is a dispersion of two immiscible liquids (one liquid phase being “dispersed” and the other being “continuous”) in which the individual droplets of the dispersed phase have an average radius less than about one-quarter the wavelength of light. Such microemulsions have also been termed “nanoemulsions”. Typically, in a microemulsion, the dispersed phase droplets have a radius of less than about 1400 Å, and preferably on the order of about 100 to about 500 Å. The basic theory of microemulsions is more fully described in Rosano, Journal of the Society of Cosmetic Chemists, 25: 609-619 (November, 1974), incorporated herein by reference.
Microemulsions can be difficult to formulate, frequently requiring the use of co-solvents, such as ethanol or propylene glycol. These co-solvents can lead to off-flavors in the final product. Further, the formation of microemulsions frequently requires some rather stressful processing conditions, such as high pressure homogenization, which require specialized equipment and can increase the cost of the final product.
It therefore would be useful to have a procedure for formulating microemulsions, using relatively low levels of food grade emulsifiers, which allow the incorporation of water-immiscible components into aqueous-based food and beverage compositions without requiring the use of such co-solvents and relatively extreme processing conditions.
The prior art describes the formation of microemulsions, as well as the use of microemulsions formed by conventional processes for the incorporation of materials into food and beverage products.
U.S. Pat. No. 4,146,499, Rosano, issued Mar. 27, 1979, describes an oil-in-water microemulsion which utilizes a high/low HLB surfactant mixture for forming the emulsion. The patent does not teach or suggest use of a ternary (high/low/medium HLB) surfactant system in forming the emulsion.
U.S. Pat. No. 4,752,481, Dokuzovic, issued Jun. 21, 1988, describes a flavored chewing gum product which includes a chewing gum base, a sweetener, and a flavor-containing emulsion. The emulsion comprises 19 to 59% of a flavoring oil, 1 to 5% of an emulsifier having an HLB of from about 1.6 to about 7.0, and an alkyl polyol (for example, glycerin or polyethylene glycol).
U.S. Pat. No. 4,835,002, Wolf et al., issued May 30, 1989, describes a microemulsion of an edible essential oil (such as citrus oil) in a water/alcohol matrix. The composition comprises water, the essential oil, alcohol and a surfactant. The surfactant component utilized must include a high HLB surfactant, although a mixture of high HLB and low HLB surfactants can also included. There is no disclosure of a ternary surfactant emulsifier system for use in forming the emulsion.
U.S. Pat. No. 5,320,863, Chung et al, issued Jun. 14, 1994, describes microemulsions used to deliver high concentrations of flavor or fragrance oils. The compositions are said to exhibit high stability even in the absence of lower alcohols. The compositions include a nonionic surfactant (generally not edible or food grade); no discussion of HLB criticality is provided. There is no disclosure or suggestion to combine high, low and medium HLB surfactants into a ternary emulsifying system.
U.S. Pat. No. 5,447,729, Belenduik et al, issued Sep. 5, 1995, describes a particulate pharmaceutical composition wherein a pharmaceutical active material may be incorporated into particles in the form of a microemulsion. The outer layers of the particles have hydrophobic/lipophilic interfaces between them. The disclosed compositions can include polysorbate 80 or glycerol monooleate as an emulsifier. There is no teaching in the patent of a ternary surfactant emulsifier system.
U.S. Pat. No. 5,948,825, Takahashi et al., issued Sep. 7, 1999, describes water-in-oil emulsions of hard-to-absorb pharmaceutical agents for use in topical or oral administration. There is no disclosure or suggestion of a ternary surfactant emulsifier system. The emulsifiers disclosed in the '825 patent can include a mixture of two types of nonionic surfactants, one having an HLB of from 10 to 20, and the other having an HLB from 3 to 7.
U.S. Pat. No. 6,048,566, Behnam et al., issued Apr. 11, 2000, describes a nonalcoholic, clear beverage which incorporates from 10 to 500 mg/l of ubiquinone Q10, together with a polysorbate stabilizer.
U.S. Pat. No. 6,077,559, Logan et al., issued Jun. 20, 2000, relates to flavored vinegars which are based on the inclusion of specifically defined microemulsions. The oil-in-vinegar microemulsions comprise from 20% to 70% vinegar, 5% to 35% ethanol, 0.1% to 5% of a flavor material, and 0.5% to 5% of a surfactant. The surfactants utilized are high HLB surfactants; they can also include a small amount of low HLB (4 to 9) surfactant. There is no disclosure of a ternary surfactant emulsifier system in the '559 patent.
U.S. Pat. No. 6,146,672, Gonzalez et al., issued Nov. 14, 2000, relates to spreadable water-in-oil emulsions which are used as fillings in pastry products, particularly frozen pastries. The fillings are said to exhibit enhanced shelf-life and stability. The described emulsions include a mixture of high and low HLB emulsifiers. Although the '672 patent describes a mixture of high and low HLB surfactants, it does not disclose or suggest the ternary surfactant emulsifier system which is utilized in the present invention. Further, the '672 patent does not teach microemulsions or the use of an emulsion to incorporate water-insoluble materials into food products.
U.S. Pat. No. 6,303,662, Nagahama et al., issued Oct. 16, 2001, describes microemulsions used in the delivery of fat-soluble drugs. The disclosed compositions require a high polarity oil, a low polarity oil, a polyglycerol mono fatty acid ester, and a water-soluble polyhydric alcohol. There is no disclosure of a ternary surfactant emulsifier system.
U.S. Pat. No. 6,376,482, Akashe et al., issued Apr. 23, 2002, describes mesophase-stabilized compositions which incorporate plant sterols as cholesterol-lowering agents. The compositions can include a mixture of a surfactant having an HLB of from 6 to 9, a surfactant having an HLB of from 2 to 6, and a surfactant having an HLB of from 9 to 22. Although this patent does teach a ternary emulsifier system, the product formed is not a microemulsion, but rather a mesophase-stabilized emulsion (the mesophase does not have separate oil and water phases). The disclosed compositions are said to provide mouth feel and texture benefits to food products. The emulsion particles formed in the '482 patent are relatively large (i.e., from about 2 to about 10 μm).
U.S. Pat. No. 6,426,078, Bauer et al., issued Jul. 30, 2002, describes oil-in-water microemulsions which comprise from 10% to 99% of a triglycerol mono fatty acid emulsifier (for example, triglycerol monolaurate, triglycerol monocaproate or triglycerol monocaprylate), 1% to 20% of a lipophilic substance (for example, beta-carotene, vitamin A or vitamin E), and water. These compositions are said to be useful in foods, cosmetics or pharmaceuticals for incorporating non-water-soluble (lipophilic) substances. There is no disclosure of a ternary surfactant emulsifier system for forming the microemulsion.
U.S. Pat. No. 6,444,253, Conklin et al, issued Sep. 3, 2002, describes a microemulsion flavor delivery system in the form of an oil-in-alcohol composition. These compositions require the use of alcohols which generally are not included in typical food or beverage formulations. Further, the '253 patent does not teach or suggest a ternary surfactant emulsifier system.
U.S. Pat. No. 6,509,044, Van Den Braak et al., issued Jan. 21, 2003, describes microemulsions of beta-carotene. These microemulsions are said to be based on an emulsifier system which preferably is a binary surfactant system, but can also be a ternary system (although there are no examples of a ternary system provided). It is taught that the fatty acid profiles of the emulsifiers are matched with the fatty acid profiles of the oily ingredient to be incorporated into the composition. There is no teaching in the '044 patent of a ternary high/low/medium HLB surfactant emulsifier system for use in forming the microemulsion.
U.S. Pat. No. 6,774,247, Behnam, issued Aug. 10, 2004, relates to aqueous ascorbic acid solutions. These solutions are said to contain an excess of an emulsifier having an HLB of from about 9 to about 18, such as polysorbate 80. There is no suggestion in the '247 patent to utilize a ternary surfactant emulsifier system.
U.S. Published Patent Application 2002/0187238, Vlad, published Dec. 12, 2002, relates to clear, stable oil-loaded microemulsions used as flavoring components in clear beverage compositions. These compositions utilize a co-solvent at a co-solvent:surfactant ratio of about 1:1. Further, the surfactant component comprises a mixture of at least two surfactants having an average HLB of from about 9 to about 18, preferably from about 12 to about 15. There is no disclosure in the '238 application of a ternary surfactant emulsifier composition comprising a mixture of low/medium/high HLB surfactants. The microemulsions defined in the '238 application comprise at least 30% oil, 1% to 30% of a surfactant mixture having an HLB of from 9 to 18, less than 20% co-solvent, and at least 35% water.
PCT Published Patent Application WO 94/06310, Ford et al., published Mar. 31, 1994, describes a colorant composition in the form of a microemulsion. Compositions disclosed in the '310 application include beta-carotene, alpha-tocopherol and ascorbic acid. Polysorbates are preferred emulsifiers in the '310 application. There is no teaching of a ternary surfactant emulsifier system in the formation of the microemulsion.
SUMMARY OF THE INVENTION
The present invention relates to microemulsions used to incorporate lipophilic water-insoluble materials into food and beverage compositions, comprising:
(a) an oil phase comprising said water-insoluble material and a low HLB emulsifier having an HLB of from about 1 to about 5;
(b) an aqueous phase; and
(c) a food grade emulsifier system comprising:
(i) an emulsifier having an HLB of from about 9 to about 17; and (ii) an emulsifier having an HLB of from about 6 to about 8;
wherein said oil phase is dispersed as particles having an average diameter of less than about 300 nm, within said aqueous phase.
The present invention also encompasses food compositions and beverage compositions which incorporate the microemulsions defined above.
The present invention also relates to a method for preparing the microemulsions defined above, comprising the steps of:
(a) mixing the lipophilic water-insoluble components with the low HLB emulsifier to form the oil phase;
(b) mixing the emulsifier system into the oil phase; and
(c) adding the aqueous phase into the product of step (b) and mixing to form the microemulsion.
Finally, the present invention relates to water-in-oil microemulsions using the ternary emulsifier system described herein, and concentrates used for making oil-in-water and water-in-oil microemulsions.
The microemulsions of the present invention provide several advantages over conventional compositions. Specifically, the microemulsions of the present invention can carry effective levels of difficult-to-disperse components, such as carotenoids, in optically transparent beverages. The compositions of the present invention are sufficiently stable under normal soft drink transport and storage conditions. The taste of the food and beverage products of the present invention is very acceptable.
The physical and optical characteristics of the emulsions are controllable by selection of appropriate emulsifiers and the heating temperature used, as well as the order of addition of the components. Importantly, the microemulsions of the present invention form essentially spontaneously under normal stirring, without requiring extreme processing conditions, such as high-pressure homogenization. Finally, the microemulsions of the present invention can demonstrate improved bioavailability of the dispersed elements, such as carotenoids.
With the present invention it is also possible to prepare oil-in-water microemulsions containing omega-3 fatty acids or their esters that are highly susceptible to oxidation (or other acids/esters which are highly susceptible to oxidation). It is observed that such components exhibit higher oxidative stability in microemulsions of the present invention than in conventional emulsions.
All patents and publications listed in the present application are intended to be incorporated by reference herein.
All ratios and proportions described in this application are intended to be “by weight,” unless otherwise specified.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides for microemulsions which are easily formed and which allow for the incorporation of water immiscible components into aqueous-based food and beverage compositions. Similarly, the microemulsions can be used to incorporate water-soluble materials into fat-based products. For example, water-soluble natural colorants, flavors, vitamins, salts or antioxidants can be incorporated into fat-based products like coating layers on a snack bar, frosting, chocolate, margarine, fat spread or confectionary products.
The water-insoluble components which may be incorporated into the food and beverage compositions of the present invention encompass any materials which are desirably incorporated into a food or beverage product, but which are insoluble in or immiscible with an aqueous-based composition. Such materials generally are lipophilic. Examples of such materials include certain colorants, flavorants, nutrients, nutraceuticals, therapeutic agents, antioxidants, extracts of natural components (such as plants, roots, leaves, flowers, etc.), medicaments, preservatives, and mixtures of these materials. Specific examples of such materials which are frequently used in food and beverage compositions include the following: carotenoids and their derivatives (such as beta-carotene, apocarotenal, lutein, lutein ester, lycopene, zeaxanthin, crocetin, astaxanthin), essential oils, edible oils, fatty acids, proteins and peptides, polyunsaturated fatty acids and their esters, vitamin A and its derivatives, vitamin E and its derivatives, vitamin D and its derivatives, vitamin K and its derivatives, colorants, flavorants, nutrients, nutraceuticals, therapeutic agents, antioxidants, extracts of natural components (such as plants, roots, leaves, flowers, seeds, etc.), medicaments, preservatives, lipoic acid, phytosterins, quercetin, phytosterols and their esters, co-enzyme Q10 (ubidecarone), plant isoflavones (such as genistein, isogenistein or formononetine), and mixtures thereof.
Particularly preferred materials which can be incorporated using the present invention include, for example, oil-soluble, oil-insoluble or water-soluble food ingredients, such as food additives, food preservatives, food supplements, antioxidants, nutraceuticals, cosmoceuticals, plant extracts, medicaments, fatty acids, peptides, proteins, carbohydrates, natural flavors, synthetic flavors, colorants, vitamins, and combinations of those materials. The specific microemulsion systems of beta-carotene, vitamin E, vitamin A materials, such as vitamin A palmitate, vitamin E acetate, and mixtures of those components are given as examples of this invention.
A key element for forming the microemulsions of the present invention is the ternary surfactant emulsifier system. It is through the use of this ternary system that microemulsions which provide the benefits of the present invention are formed. This ternary emulsifier system is a mixture of at least three food grade emulsifiers in the form of nonionic or anionic surfactants. Nonionic surfactants are preferred. Nonionic surfactants are well known in the art and are described, for example, in Nonionic Surfactants: Organic Chemistry , Nico M. van Os (ed.), Marcel Dekker, 1998. At least one of the emulsifiers has a low HLB (i.e., from about 1 to about 5), at least one of the emulsifiers has a medium HLB (i.e., from about 6 to about 8), and at least one of the emulsifiers has a high HLB (i.e., from about 9 to about 17, preferably from about 10 to about 16).
The selection of the particular surfactants used in the ternary emulsifier system depends on the HLB (hydrophilic-lipophilic balance) value of such surfactants. The surfactants are selected such that they have the HLB values described above. The HLB value, and the determination thereof, for surfactants is well known in the art and is disclosed, for example, by Milton J. Rosen in Surfactants and Interfacial Phenomena , J. Wiley and Sons, New York, N.Y., 1978, pages 242-245, or in the Kirk - Othmer Encyclopedia of Chemical Technology, 3rd edition, volume 8, 1979, at pages 910-915, both incorporated herein by reference.
The following table sets forth the HLB values for a variety of anionic and nonionic surfactants which can, as examples, be used in the ternary system of the present invention. The HLB of other non-listed surfactants can be calculated using procedures well known in the art.
HLB Value*
Anionic Surfactant
myristic acid
22
palmitic acid
21
stearic acid
20
oleic acid
20
monoglyceride ester of diacetyltartaric acid
9.2
digylceride ester of diacetyltartaric acid
3.2
monoglyceride ester of citric acid + and salts
27
thereof
diglyceride ester of citric acid
20
monoglyceride ester of lactic acid
21
diglyceride ester of lactic acid
14
dioctyl sodium sulfosuccinate
18
monoglyceride ester of phosphoric acid
14
diglyceride ester of phosphoric acid
8
lecithin
7 to 9
hydroxylated lecithin**
8 to 9
Nonionic Surfactants
polysorbates
10 to 18
sorbitan ester of myristic acid
6.7
sorbitan ester of palmitic acid
5.7
sorbitan ester of stearic acid
4.7
sorbitan ester of oleic acid
4.7
polyglycerol esters of myristic acid
3 to 16 depending on
polyglycerol esters of palmitic acid
the number of glycerol
polyglycerol esters of stearic acid
units and fatty acid
polyglycerol esters of oleic acid
side chains
present therein
monoglyceride ester of myristic acid
4.8
monoglyceride ester of palmitic acid
4.3
monoglyceride ester of stearic acid
3.8
monoglyceride ester of oleic acid
3.1
diglyceride ester of myristic acid
2.3
diglyceride ester of palmitic acid
2.1
diglyceride ester of stearic acid
1.8
diglyceride ester of oleic acid
1.8
(ethoxy)n monoglyceride of myristic acid***
13 to 21
(ethoxy)n monoglyceride of palmitic acid***
(ethoxy)n monoglyceride of stearic acid***
(ethoxy)n monoglyceride of oleic acid***
(ethoxy)n diglyceride of myristic acid***
7 to 15
(ethoxy)n diglyceride of palmitic acid***
(ethoxy)n diglyceride of stearic acid***
(ethoxy)n diglyceride of oleic acid***
sucrose ester of myristic acid
18
ester of palmitic acid
17
ester of stearic acid
16
ester of oleaic acid
16
propylene glycol ester of myristic acid
4.4
ester of palmitic acid
3.9
ester of stearic acid
3.4
ester of oleaic acid
4.3
*in fully ionized form in water at 20–25° C.
**amphoteric depending on pH of matrix
***wherein n is a whole number from 10 to 30
Any edible oil may be used as the oil phase in the present compositions. Specifically, the oil phase can be selected from edible fat/oil sources, such as the oil extracts from natural components (e.g., plants, flowers, roots, leaves, seeds). For example, these materials can include carrot seed oil, sesame seed oil, vegetable oil, soybean oil, corn oil, canola oil, olive oil, sunflower oil, safflower oil, peanut oil, or algae oil. Also included are flavor oils, animal oils (such as fish oils), and dairy products (such as butterfat). The oil phase can be made from pure oil, mixtures of different oils, or a mixture of different oil-soluble materials, or mixtures thereof.
In the oil-in-water microemulsions of the present invention the low HLB surfactant is present at from about 0.1% to about 5%, particularly about 0.7% to about 1%, of the microemulsion. The high HLB surfactant is present at from about 5% to about 25%, particularly from about 12% to about 18%, of the microemulsion. The medium HLB surfactant is present at from about 0.1% to about 5%, particularly from about 0.5% to about 1.5% of the microemulsion. Particularly preferred low HLB surfactants include glycerol monooleate, polyglycerol riconoleate, decaglycerol decaoleate, sucrose erucate and sucrose oleate. Particularly preferred medium HLB surfactants are polyglycerol esters, such as decaglycerol hexaoleate, and triglycerol monofatty acids, such as triglycerol monooleate, and sucrose stearate. Particularly preferred high HLB surfactants include polysorbate 80 or polyoxysorbitan monolaurate (commercially available as the TWEEN® series of surfactants), polyglycerol-6 laurate, decaglycerol lauric acid esters, decaglycerol oleic acid esters and sucrose esters.
In one embodiment of the microemulsions of the present invention, the oil phase is dispersed within the aqueous phase (i.e., an oil-in-water (o/w) microemulsion). The oil phase is present in particulate form, having a particle size mean diameter of less than about 300 nm, such as from about 1 to about 300 nm, preferably from about 1 to about 200 nm. The aqueous phase typically comprises water and the water-soluble ingredients of the composition, and is present at from about 50% to about 90%, preferably from about 70% to about 85%, of the microemulsion. The oil phase generally comprises from about 1% to about 15%, preferably from about 2% to about 6%, of the microemulsion. Typically, the oil phase includes the water-insoluble components, as they have been defined above, together with the low HLB emulsifier component.
This oil-in-water microemulsion of the present invention, described above, can be formulated in a relatively simple manner as follows. The lipophilic water-insoluble components are mixed with the low HLB emulsifier to form the oil phase. Heat may be applied, if necessary, to melt the insoluble components and/or the surfactant to form the oil phase. The emulsifier system, which comprises the high HLB and the medium HLB emulsifiers is then formed and mixed into the oil phase. The aqueous phase is then added into the previously made (oil phase/emulsifier) mixture and further mixed to form the microemulsion. The mixing which is required to form the microemulsion is relatively easy mixing. Typical equipment which can be used to mix the components to form the microemulsion include, for example, a magnetic stirrer or an overhead mixer.
In selecting the emulsifiers utilized in the microemulsions of the present invention, the following criteria may also be important. The high HLB emulsifier should have an HLB value between about 9 and about 17, preferably between about 10 and about 16. Without wishing to specify a particular mechanism of action of the emulsifiers, it may be advantageous to use emulsifiers with relatively bulky head groups and non-bulky tails selected as to their length so they can form micelles readily. This is the major emulsifier which confers water-soluble characteristics to the system. The hydrophilic portions of the molecule repel each other sideways to curve the interface around the oil side and promote the formation of the oil-in-water microemulsions. The low HLB emulsifier must be lipophilic and have an HLB value between about 1 and about 5. This minor emulsifier stays within the oil phase and acts as a co-surfactant. The emulsifier molecules align their heads and tails in nearly a perfect way with the oil and the first hydrophilic surfactant to promote formation of micelles as small as possible. The third emulsifier has a medium HLB between about 6 and about 8. This minor emulsifier can stay in either the water or oil phase and also acts as a co-surfactant. It is believed that this emulsifier not only further reduces the interfacial tension between droplets, but also tends to bend the interface to make the droplets smaller. The combination of the very low interfacial tension, long hydrophobic tails of the first emulsifier and close packing, and the effect of the co-surfactants on the curvature of the interface provides a dispersed and stable system of small droplet size. Examples of food grade surfactants which can be used in the microemulsions of the present invention include polysorbates (ethoxylated sorbitan esters), such as polysorbate 80; sorbitan esters, such as sorbitan monostearate; sugar esters, such as sucrose laurate; polyglycerol esters of fatty acids (from mono-, di-, tri-, and up to deca-, glycerol esters of fatty acids), mono and diglycerides, combinations of fatty acids and ethoxylated mono-diglycerides, and mixtures thereof.
In addition to the oil-in-water microemulsions described above, the present invention also encompasses water-in-oil (w/o) microemulsions. These are particularly useful for incorporating water-soluble materials into oil- or fat-based compositions. In these water-in-oil microemulsions, the aqueous phase is dispersed in the oil phase. The aqueous phase is present in particulate form, having a particle size mean diameter of less than about 300 nm, such as from about 1 to about 300 nm, preferably from about 1 to about 200 nm. The aqueous phase typically comprises water and the water-soluble ingredients of the composition, and is present at from about 1% to about 15%, preferably from about 2% to about 6%, of the microemulsion. The oil phase includes the water-insoluble components and the oily/fatty base, and is generally present at from about 50% to about 90%, preferably from about 70% to about 85%, of the microemulsion. In forming these water-in-oil microemulsions, the water-soluble components are mixed with the high HLB emulsifier to form the aqueous phase. The low HLB and medium HLB emulsifiers are then mixed together and added to the aqueous phase. The oil phase is then added to the aqueous phase with mixing, for example, with an overhead mixer to form the water-in-oil microemulsion. Typically, in water-in-oil microemulsions, the high HLB surfactant is present at from about 0.1% to about 5%, the medium HLB surfactant is present at from about 0.1% to about 5%, and the low HLB surfactant is present at from about 5% to about 30%, of the final composition.
Physical properties of the microemulsion composition, and the final product, can be adjusted by increasing or decreasing the amount of oil or water in the dispersed phase of the microemulsion.
Finally, the present invention encompasses concentrate microemulsion systems which comprise the dispersed phase (including the component(s) which is (are) to be incorporated into the final composition) and the three emulsifiers defined herein; the concentrate does not include the continuous phase. The concentrate is added to the continuous phase, with stirring, and the microemulsion is formed. Thus, in a concentrate to form an oil-in-water microemulsion, there will be included an oil-based phase of selected lipid-soluble ingredients, together with the ternary emulsifier system, with no aqueous phase. This concentrate is added to an aqueous phase, with mixing, to form the oil-in-water microemulsion. On the other hand, for a concentrate to form a water-in-oil microemulsion, there will be an aqueous phase of particular water-soluble ingredients, together with the ternary emulsifier system, with no oil phase. Examples of such concentrates are described in this application. These concentrates that will form oil-in-water microemulsions comprise from about 1% to about 40% of the disperse phase, and from about 1% to about 10% of the low HLB emulsifier, from about 1% to about 10% of the medium HLB emulsifier, and from about 65% to about 95% of the high HLB emulsifier. These concentrates that will form water-in-oil microemulsions comprise from about 1% to about 40% of the dispersed phase, and from about 65% to about 95% of the low HLB emulsifier, from about 1% to about 10% of the medium HLB emulsifier, and from about 1% to about 10% of the high HLB emulsifier. The concentrate is added, with mixing, to the continuous phase such that the final microemulsion composition comprises from about 1% to about 15% (preferably from about 2% to about 6%) of the dispersed phase, and from about 50% to about 99% (preferably from about 70% to about 85%) of the continuous phase.
The microemulsions of the present invention may be incorporated into aqueous-based or lipid-based food and beverage products. These products are conventional and are well known in the art. Examples and information about the formulation of such products may be found in the Encyclopedia of Food Sciences and Nutrition , by Benjamin Caballero, Luis C. Trugo and Paul M. Finglas (editors), 2nd Edition, London: Academic, 2003, or in the Dictionary of Food Compounds with CD - ROM: Additives, Flavors and Ingredients , edited by Shmuel Yannai, Boca Raton, Fla., CRC Press, 2004, or in The Soft Drinks Companion: A Technical Handbook for the Beverage Industry , by Maurice Shachman, Boca Raton, Fla., CRC Press, 2005, all of which are incorporated herein by reference.
The microemulsions of the present invention may be incorporated into those products using the following conventional techniques. The microemulsions can be incorporated into those products as color, flavor or other types of food ingredients. The microemulsions can simply be added and mixed or diluted directly into aqueous-based or lipid-based food and beverage compositions using typical mixers or stirrers. The speed with which the microemulsion systems are incorporated into food and beverage products depends on the velocity at which individual components in the microemulsions dissolve into the specific food and beverage systems; typically the products can be homogeneous within 5 minutes. The speed of incorporation of microemulsions into various systems could be accelerated by increasing the speed of mixing and/or possibly warming the food systems to about 40° C., if it is necessary.
In addition to the components described above, the food and beverage compositions, as well as the microemulsions of the present invention, may include adjunct components conventionally used in food or beverage products at their art-established levels. Examples of such components include preservatives, antioxidants, flavorants, colorants, nutrients, nutraceuticals, food supplements, antioxidants, plant extracts, therapeutic agents (for example, chondroitin or electrolytes), and combinations of those materials. To the extent such components are water-immiscible or lipid-immiscible, they may be incorporated into the food and beverage compositions using the microemulsions of the present invention.
By using the compositions and methods of the present invention, it is possible to form effective microemulsions without the use of co-solvents, such as ethanol and propylene glycol. These co-solvents can result in off-flavors in the food or beverage compositions. In addition, the microemulsions of the present invention are formed using lower levels of surfactants than are typically needed in microemulsion formation. Because of this, the microemulsions of the present invention exhibit less off-flavor caused by surfactants, are able to carry high levels of difficult-to-disperse ingredients, and are more stable either in concentrated or dilute form. In addition, the present invention allows for the preparation of stable compositions containing difficult-to-disperse ingredients (such as beta-carotene). Beta-carotene is highly insoluble and tends to recrystallize, hence breaking a typical microemulsion system). The present invention allows for a stable composition of such materials, such as beta-carotene, formed in a way which does not require extreme processing conditions. Further, the microemulsions of the present invention, as well as the food and beverage products containing them, have a controllable appearance in that by adjusting the types and concentrations of surfactants and/or the oil phase, the optical properties, from crystal clear to cloudy, can be adjusted in the finished product.
The following examples are intended to be illustrative of various embodiments of the present invention and are not intended to be limiting of the invention definition in any way.
Example 1—Beta-Carotene Oil-in-Water Microemulsion
The following is an example of the preparation of a beta-carotene oil-in-water microemulsion of the present invention. The microemulsion has the following composition:
Component
Weight %
Water, deionized
79.335
Sodium benzoate agglomerate
0.075
Ascorbic acid
0.20
Polysorbate 80 (TWEEN ®) - high HLB
15.00
Triglyceryl monostearate - medium HLB
1.00
Beta-carotene (30% suspension in vegetable oil)
3.36
Vitamin E (tocopherol alpha)
0.10
Vitamin A palmitate
0.10
Glyceryl monooleate - low HLB
0.83
Total
100.000
The above ingredients are prepared in three separate parts: (1) a water phase (water, sodium benzoate and ascorbic acid); (2) a mixture of emulsifiers containing the high and medium HLB materials (polysorbate and Triglyceryl monostearate); and (3) an oil phase which comprises the water-insoluble components and the low HLB emulsifier (beta-carotene 30%, vitamin E, vitamin A and glycerol monooleate). Heat is used to melt the beta-carotene and surfactant so that the components form a single liquid phase. These three parts are then added in the following order to form a concentrated microemulsion:
In the first vessel, prepare the aqueous phase by adding sodium benzoate to deionized water. Mix for 5 minutes with medium agitation until the powder is completely dissolved. Add ascorbic acid and mix for 5 minutes. In the second vessel, prepare the emulsifier phase by combining polysorbate 80 (TWEEN®) and polyglycerol ester (tryglyceryl monostearate). Mix well until it is homogeneous. In the heating kettle, prepare the oil phase by combining beta-carotene 30% oil, glyceryl monooleate, vitamin A palmitate and alpha tocopherol. After the oil phase is completely mixed, heat the kettle containing beta-carotene, vitamin E, vitamin A and glyceryl monooleate to 280-285° F. with medium agitation until beta-carotene crystals are completely dissolved. Immediately add the oil phase from the kettle to the emulsifier phase in the second vessel, then mix for an additional 5 minutes or until homogeneous. Then add the aqueous phase (water/sodium benzoate/ascorbic acid) from the first vessel to the mixture of the oil phase and emulsifier in the second vessel. Mix at high speed for 15 minutes or until the microemulsion is uniform. The microemulsion can then be diluted to the desired concentration and added to a food or beverage product.
Examples of commercial sources of emulsifiers suitable for use in the present invention, include, but are not limited to, Abitec ADM, BASF, Danisco, ICI, Lambent Technologies, Lonza, Mitsubishi Chemical, and Stepan.
Example 2—Lemon Oil-in-Water Microemulsion
Component
Weight %
Water, deionized
77.225
Sodium benzoate agglomerate
0.075
Ascorbic acid
0.20
Decaglycerol lauric acid ester - high HLB
16.67
Decaglycerol oleic acid ester - medium HLB
1.67
Lemon oil
3.33
Sucrose oleate - low HLB
0.83
Total
100.00
First, mix 16.67 g of decaglycerol lauric acid ester with 1.67 g of decaglycerol oleic acid ester. Second, mix 3.33 g of lemon oil with 0.83 g of sucrose oleate in a separate container, then add to the mixture obtained above. Third, mix sodium benzoate with deionized water before adding ascorbic acid. Then add the aqueous phase to the mixture from step two. Microemulsion is obtained by mixing, using an overhead mixer. The entire process is done at room temperature. This system can be diluted with any amount of water.
Example 3—Paprika Oil-in-Water Microemulsion
Component
Weight %
Water, deionized
71.00
Sodium benzoate agglomerate
0.075
Ascorbic acid
0.20
Decaglycerol lauric acid ester - high HLB
25.00
Decaglycerol tetraoleate - medium HLB
1.67
Paprika oleoresin
1.00
Decaglycerol decaoleate - low HLB
1.00
Total
100.00
First, mix 25 g of decaglycerol lauric acid ester with 1.67 g of decaglycerol tetraoleate. Second, mix 1 g of paprika oleoresin with 1 g of decaglycerol decaoleate in a separate container, then add to the mixture obtained above. Third, mix sodium benzoate with deionized water before adding ascorbic acid. Then add the aqueous phase to the mixture from step two. Microemulsion is obtained by mixing, using an overhead mixer. The entire process is done at room temperature. This system can be diluted with any amount of water.
Example 4—Beet Juice Water-in-Oil Microemulsion
Component
Weight %
Cottonseed oil
74.64
Polysorbate 80 - high HLB
1.49
Triglycerol monooleate - medium HLB
1.49
Beet juice
7.46
Polyglycerol ricinoleate - low HLB
14.92
Total
100.00
First, mix 7.46 g of beet juice and 1.49 g of polysorbate 80. Second, mix 1.49 g of triglycerol monooleate with 14.92 g of polyglycerol ricinoleate in a separate container, then add to the mixture obtained above. Third, cottonseed oil is added to the mixture from step two. Concentrate beet juice water-in-oil microemulsion system is obtained by mixing, using an overhead mixer. The entire process is done at room temperature. This system can be diluted with any amount of edible vegetable or mineral oil or lipid-based systems provided the system does not contain substantial levels of emulsifier (s).
Example 5—Aronia Extract Water-in-Oil Microemulsion
Component
Weight %
Canola oil
70.17
Decaglycerol monocaprylate - high HLB
1.75
Decaglycerol tetraoleate - medium HLB
1.75
Aronia extract
8.77
Polyglycerol ricinoleate - low HLB
17.54
Total
100.00
First, mix 8.77 g of aronia extract (natural water-soluble colorants) and 1.75 g of decaglycerol monocaprylate. Second, mix 1.75 g of decaglycerol tetraoleate with 17.54 g of polyglycerol ricinoleate in a separate container, then add to the mixture obtained above. Third, canola oil is added to the mixture from step two. Concentrate aronia extract water-in-oil microemulsion system is obtained by mixing, using an overhead mixer. The entire process is done at room temperature. This system can be diluted with any amount of edible vegetable or mineral oil or lipid-based systems provided the system does not contain substantial levels of emulsifier (s).
Example 6—Elderberry Extract Water-in-Oil Microemulsion Concentrate
Component
Weight %
Polyethyleneglycol monooleate - high HLB
5.89
Decaglycerol hexaoleate - medium HLB
5.89
Elderberry extract
29.41
Decaglycerol decaoleate - low HLB
58.82
Total
100.00
First, mix 29.41 g of elderberry extract (natural water-soluble colorants) and 5.89 g of polyethyleneglycol monooleate. Second, mix 58.82 g of decaglycerol tetraoleate with 5.89 g of decaglycerol hexaoleate in a separate container, then add to the mixture obtained above to form the concentrate. Canola oil is added to the mixture from step two to form the microemulsion by mixing using an overhead mixer. The entire process is done at room temperature. This system can be diluted with any amount of edible vegetable or mineral oil or lipid-based systems provided the system does not contain substantial levels of emulsifier (s).
Example 7—Alpha-Tocopherol Oil-in-Water Microemulsion Concentrate
Component
Weight %
Polysorbate 20 (TWEEN ®) - high HLB
85.00
Triglycerol monooleate - medium HLB
5.00
Alpha-tocopherol
6.67
Decaglycerol decaoleate - low HLB
3.33
Total
100.00
First, mix 6.67 g of alpha-tocopherol (vitamin E) and 3.33 g of decaglycerol decaoleate. Second, mix 5 g of triglycerol monooleate with 85 g of polysorbate 20 in a separate container, then add to the mixture obtained above. Concentrate alpha-tocopherol microemulsion (micellar) system is obtained by mixing, using an overhead mixer. The entire process is done at room temperature. This system can be diluted with any amount of water.
Example 8—Vitamin E Acetate Oil-in-Water Microemulsion Concentrate
Component
Weight %
Decaglycerol lauric acid ester - high HLB
89.26
Decaglycerol tetraoleate - medium HLB
1.65
Vitamin E acetate
7.44
Glyceryl monooleate - low HLB
1.65
Total
100.00
First, mix 7.44 g of vitamin E acetate and 1.65 g of glyceryl monooleate. Second, mix 1.65 g of decaglycerol tetraoleate with 89.26 g of decaglycerol lauric acid ester in a separate container, then add to the mixture obtained above. Concentrate vitamin E acetate microemulsion (micellar) system is obtained by mixing, using an overhead mixer. The entire process is done at room temperature. This system can be diluted with any amount of water.
Example 9—Beverage with Vitamin E Microemulsion
Component
Weight %
Water
86.67
Sucrose
6.00
Citric acid
1.00
Ascorbic acid
0.30
Apple juice
5.00
Pineapple juice
1.00
Vitamin E microemulsion
0.03
(e.g., see Example 8)
Total
100.00
First, mix 6 g of sucrose, 1 g of citric acid and 0.3 g of ascorbic acid with 86.67 g of water. Second, add 5 g of apple juice, 1 g of pineapple juice and 0.3 g vitamin E microemulsion into the solution of step one, and mix until homogeneous using a stirrer or an overhead mixer. The entire process is done at room temperature. This system can then be passed through a thermal process, such as pasteurization or sterilization, to prevent microbial spoilage.
Example 10—Beverage with Beta-Carotene Microemulsion
Component
Weight %
Water
86.44
Sucrose
12.00
Citric acid
1.30
Ascorbic acid
0.20
Orange flavor
0.05
Beta-carotene microemulsion (e.g., see Example 1)
0.01
Total
100.00
First, mix 12 g of sucrose, 1.03 g of citric acid and 0.2 g of ascorbic acid with 86.44 g of water. Second, add 0.05 g of orange flavor and 0.01 g of beta-carotene emulsion into the solution formed in step one, and mix until homogeneous using a stirrer or an overhead mixer. The entire process is done at room temperature. This system can then be passed through a thermal process, such as pasteurization or sterilization, to prevent microbial spoilage.
Example 11—Icing with Aronia Extract Natural Color Microemulsion
Component
Weight %
Confectioners sugar
77.88
Canola oil
11.88
Water
9.11
Cream of tartar
0.77
Salt
0.45
Aronia extract microemulsion (e.g., see Example 5)
0.17
Total
100.00
First, mix 77.8 g of confectioners sugar, 0.77 g of cream of tartar and 0.45 g of salt with 9.11 g of water and 11.88 g of canola oil. Then add aronia extract microemulsion to the mixture formed in step one. Mix thoroughly until homogeneous. The entire process is done at room temperature.
While this invention has been described with reference to certain specific embodiments, it will be recognized by those skilled in the art that many variations are possible without departing from the scope and spirit of the invention. Further, it will be understood that the present application is intended to cover all changes and modifications of the invention disclosed herein for the purposes of illustration which do not constitute departure from the spirit and scope of the invention.
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Oil-in-water microemulsions which can be used to incorporate lipophilic water-insoluble materials, such as beta-carotene, into food and beverage compositions are disclosed. The microemulsions utilize a ternary food grade emulsifier system which incorporates a low HLB emulsifier, a medium HLB emulsifier, and a high HLB emulsifier. The microemulsions of the present invention allow for the incorporating of water-insoluble materials in an effective and easy-to-process manner while providing formulational flexibility and without significantly affecting the taste of the underlying food or beverage product. Food and beverage products including the microemulsions are also disclosed. Finally, the method of preparing the microemulsions is described. The invention also encompasses water-in-oil microemulsions for use in incorporating water-soluble materials into food and beverage products. Finally, the invention encompasses concentrate compositions used for making those microemulsions.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to the field of tube strengthening. More particularly, the present invention relates to a reinforcing liner for use in pipe rehabilitation, wherein the liner is saturated with curable resin, introduced into a tube or pipe, shaped to conformingly line the pipe, and cured in place so as to form a rigid liner.
[0003] 2. Discussion of Related Art
[0004] Various methods of rehabilitating a tube, such as a pipe that is buried underground are known in the art. Generally speaking, such methods include the use of a liner having a diameter that is substantially the same as the inner diameter of the pipe to be rehabilitated. The liner frequently includes an impermeable layer and an adjacent resin-absorbing layer. This resin-absorbing layer is soaked with a liquid resin prior to the introduction of the liner into the pipe. After being properly positioned in the pipe, the liner is pressed against the inner surface of the pipe by fluid pressure.
[0005] Most liners in such applications utilize a layer of nonwoven felt for the resin-absorbing layer of the liner. One of the purposes of the felt is to provide support for the uncured resin of the impregnated liner. The felt serves as a reservoir and/or carrier means for the uncured resin. Once cured, the resin provides the structural strength of the liner.
[0006] These so-called cured-in-place liners are typically installed in environments that are continuously exposed to water and other corrosive materials. Cured-in-place liners are also exposed to varying temperatures and flow conditions.
[0007] The below-referenced U.S. patents disclose embodiments that were at least in part satisfactory for the purposes for which they were intended. The disclosures of all of the prior United States patents discussed herein are hereby expressly incorporated by reference into the present application in their entireties for purposes including, but not limited to, indicating the background of the present invention and illustrating the state of the art.
[0008] Wood's U.S. Pat. No. 4,390,574 discloses an inversion (called eversion) liner that is strengthened by blowing chopped glass fibers on to the web prior to a needling stage. The needling “entangles” the chopped glass fibers with the fibers of the web.
[0009] Wood's U.S. Pat. No. 4,836,715 also discloses a liner. However, this later Wood patent generally discusses with disfavor liners having polyester fibers extending orthogonally to the plane of the liner material caused by needling. According to Wood, the tensile strength of a liner is negatively impacted by fibers orientated this way. Thus, this Wood patent attempts to solve this by adding layers of reinforcing fibers, including glass, orientated in a circumferential direction.
[0010] U.S. Pat. No. 4,902,215 and U.S. Pat. No. 5,052,906, issued to William H. Seemann, address the use of a flow medium fed by a “pervious conduit” (a resin feed or channel) communicating with the flow medium, to combine use of core materials with resin flow features and reusable vacuum bags with integral resin feeds and distribution networks.
[0011] Persson's U.S. Pat. No. 5,445,875 discusses the use of chopped glass fibers in a pipe liner.
[0012] Kittson et al. U.S. Pat. No. 5,836,357 (and divisionals U.S. Pat. Nos. 5,873,391, 5,911,246, and 5,931,199) discloses an inversion liner constructed of several layers of materials. Two of these layers contain chopped glass fibers. The glass fibers are stitched or sewn on to a polyester felt and are randomly orientated in an x-y plane.
[0013] The prior art as described in U.S. Pat. Nos. 5,240,533, 5,480,697, and 6,037,035 demonstrate an “integrated sandwich structure”. The patents generally provide for a means of manufacturing (weaving) the “integrated sandwich structure” so as to optimize the structure's ability to maintain x and y fiber plane separation during composite processing.
[0014] Smith's U.S. Pat. Nos. 6,708,729 and 6,932,116 disclose a reinforced liner consisting of several layers, one of which includes reinforced fibers, preferably carbon or glass. It is further disclosed that these fibers may be arranged in one axis, in one plane or randomly in all three axes, such as with standard felt. However, the preferred alignment is circumferential.
[0015] Woolstencroft et al.'s U.S. Pat. Nos. 6,837,273 and 7,096,890 disclose the use of chopped glass fibers mechanically bonded to a flexible felt layer. The fibers can be bonded to the flexible layer by a light needling process that keeps the majority of glass fibers “properly” orientated, i.e., in the x-y plane.
[0016] Mack et al.'s U.S. Pat. Nos. 7,060,156 and 7,048,985 disclose a three-dimensional “spacer” fabric for laminates and discusses various “z direction” reinforcing fibers that can be used including glass fibers.
[0017] Many of these previously recognized solutions have the disadvantage of being not completely effective and having a relatively high cost. Further, in many instances of cured-in-place pipelining, the final product fails to meet the required ASTM standards. If these standards are not met, then catastrophic failure of the liner is possible due to the external buckling pressure exerted by the hydrostatic load and soil compaction or lack of compaction.
[0018] In some cases, point load failure is probable because the liner's cross sectional thickness is increased too much. This reduces the internal diameter of the host pipe which can result in loss of hydraulic capacity. Where point loading is not a problem, the amount of head pressure used to install a typical liner often times compresses the cross sectional thickness below an acceptable level as determined by the ASTM standards for cured-in-place pipe.
[0019] What is needed therefore is an invertible liner that may be used with the smaller diameter tubes. What is further needed is a liner that insures that ASTM standards are consistently met without dramatically increasing the cost of the finished product. What is also needed is a liner that has a flexible, three-dimensional weave or knit design. What is also needed is a system with installation processes that are similar to current processes so that installers do not need to be retrained.
SUMMARY AND OBJECTS OF THE INVENTION
[0020] By way of summary, the present invention is generally directed to a liner with fibers needle punched into a flexible mat to better fit and reinforce a pipe or tube.
[0021] In one embodiment, the invention is preferably a high tensile strength fiberglass-reinforcing member for tubular structures. For example, the member is used for at least one of the following: oil pipe, HVAC duct, water main, gas main, potable water pipe, manhole line, and sewer. The member preferably comprises a mat that includes an absorbent fabric or felt, a flexible, three-dimensional material on top of the felt, and a fiberglass on top of the felt. The fiber may be a chopped fiber, carbon fiber, glass flake, chunks, glass particles of uniform or non-uniform thickness, or any combination thereof. A second layer of fabric or felt may be added on top and a cover or coating may be added on one side of this felt. The felt preferably prevents wrinkling of the member.
[0022] In one preferred embodiment, the mat is needled to create a monolithique sandwich. For example, the layers of the mat are held together by fiberglass fragments orientated perpendicular to the felt. Preferably, the inventive mat is formed by punching or needling the fiber all the way through the layers. Once punched, the fiber orientated in the Z-position also assists in soaking and curing the mat by allowing an agent, e.g., resin, to more thoroughly soak into the felt layers.
[0023] For larger pipes, the mat is added to another mat of a similar configuration to form another mat layer. These mat layers may be joined together by stitching, flame bonding, or taping together or any combination thereof.
[0024] The cover prevents the resin or other agent from oozing out of the mat when the mat is applied to a tube. In one embodiment, the cover is a foil comprised of at least one of the following: a nylon blend or PET.
[0025] Once inverted into a tube or pipe, an agent is added to the mat for hardening or fixing the mat in place. The agent is at least one of the following: a resin, an epoxy, phenolic, polyester, urethane, vinylester, polyimide, and peroxide. The agent is applied by at least one of the following: wetting, impregnating, saturating, and soaking. This is accomplished by, e.g., applying the resin with a resin slug and a pinch roller. The resin prevents wicking.
[0026] In one embodiment, the member is an invertible fiberglass liner for a twelve-inch or less tube. In another embodiment, the member is pulled in place.
[0027] The unique configuration of members minimizes effects of load buckling, and redistributes the load. For example, it transfers load in a spiral rather than just in a hoop and down the pipe direction. Thus, the load is preferably transferred at 0, 45, 90 degrees.
[0028] These, and other aspects and objects of the present invention, will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following description, while indicating preferred embodiments of the present invention, is given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] A clear conception of the advantages and features constituting the present invention, and of the construction and operation of typical mechanisms provided with the present invention, will become more readily apparent by referring to the exemplary, and therefore non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, wherein like reference numerals designate the same elements in the several views, and in which:
[0030] FIG. 1 illustrates a perspective view of a conventional lining hose appropriately labeled “PRIOR ART”;
[0031] FIG. 2 illustrates a perspective view of one embodiment of a member according to the present invention;
[0032] FIG. 3 illustrates a schematic view of a material of the present invention;
[0033] FIG. 4 illustrates a schematic view of a sandwiched material of the present invention;
[0034] FIG. 5 illustrates a schematic view of another material according to the present invention;
[0035] FIG. 6 illustrates a schematic view of another material according to the present invention;
[0036] FIG. 7 illustrates a cross-sectional view of one portion of the member of the presents invention; and
[0037] FIG. 8 shows the member of the present invention in place in a pipe.
[0038] It should be noted that the shading in the FIGS. is meant to differentiate between the various layers and not to represent a particular material, graphical symbol, or color, unless otherwise indicated.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0039] The present invention and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments described in detail in the following description.
1. System Overview
[0040] When rehabbing piping under the ground, the pipes or lines do not normally have to be excavated. For example, current fiberglass reinforcing liners are normally pulled in place. Invertible liners are also used for rehab. However, these are generally restricted to a diameter size that can be successfully inverted.
[0041] While the present invention can be pulled into place, it is preferably an invertible glass reinforced cured-in-place polyester liner. The liner of the present invention preferably has a polyester fabric or felt layer. A knit or woven layer is added that is comprised of a corrosion resistant glass and high tenacity polyester fiber combination. The felt and knit layers are preferably needle punched with corrosion resistant glass, e.g., ECR, of varying denier sizes. A coating is preferably added to the outside of the felt layer. This coating may consist of Urethane, TPU, PVC, PE, PP, and combination there of. All of these layers combined together make a composite substrate that is then constructed into a soft flexible tube of any size.
[0042] It should be noted that the combination of such materials in layers, when placed under strain, distributes the load evenly around a given point. This thereby reduces point load failure due to increased hydrostatic pressure and yet maintains minimum cross sectional thickness of the liner.
2. Detailed Description of Preferred Embodiments
[0043] In describing the preferred embodiment of the invention, which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents, which operate in a similar manner to accomplish a similar purpose. For example, the words “connected”, “attached”, or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.
[0044] FIG. 1 shows a prior art liner as discussed above.
[0045] Referring now to FIGS. 2-8 , it can be seen that the present invention is a liner for reinforcing a tube.
[0046] By way of example from U.S. Pat. No. 5,868,169, FIG. 1 of the present application shows lining hose 1 with an inner layer of resin-absorbing material 2 comprising a layer of nonwoven polyester felt of two-eight mm in thickness. The layer of reinforcing fibers 3 is a relatively thin, up to two mm thick, mesh of fiberglass fibers. The outer layer of resin-absorbing material 4 is a two-eight mm thick layer of nonwoven polyester felt. The thickness of the various layers depends upon such factors as the size, length and depth of a given pipe to be lined. However, it should be noted that the layer of felt can be a deterrent to the strength of the liner after the resin has cured since it occupies space that could otherwise be filled with resin. An impermeable plastic material comprises the outer covering or layer 5 . Examples of the plastic material used for layer 5 include polyurethane, polypropylene and polyethylene.
[0047] Prior to inserting the lining hose into the pipe to be lined, the resin absorbent material of lining hose 1 shown in FIG. 1 is soaked with a volume of resin that exceeds the volume required to totally saturate the inner and outer layers of resin absorbent material, layers 2 and 4 respectively. The inner and outer layers of resin absorbent material may be saturated with resin using vacuum impregnation or injection methods that are commonly known in the art. The lining hose 1 must be saturated with a sufficient volume of resin so that the layer of reinforcing fibers 3 , as shown in FIG. 1 , is encapsulated in resin during both the uncured and cured stages of installation. Reinforcing layer 3 has reinforcing fibers that are shown as longitudinal fibers 31 , which are parallel to the longitudinal axis of the lining 1 and radial fibers 32 which are generally radial to that axis.
[0048] The introduction of resin may be performed directly at the installation site or at an appropriate off-site location. After the volume of resin has been introduced into the lining hose, the outer covering layer 5 is perforated so as to provide the outer covering layer with flowthrough openings 21 as illustrated in FIG. 1 .
[0049] FIG. 2 is a perspective view of a liner of the present invention. The present invention includes a member 10 which is preferably an inverted liner comprised of a mat 20 . The mat 20 includes several components. For example, the mat 20 preferably includes a three-dimensional material 25 adjacent at least one layer of felt material 40 . A second felt layer 50 may be added. Between the three-dimensional material 25 and the first felt layer 40 is layer 35 of fiberglass 37 and 37 a , which is laid on the felt 40 . On the second layer of felt 50 , is preferably a coating or cover 60 .
[0050] Prior to installation, the mat 20 is preferably soaked with a resin 65 that preferably penetrates through all the layers.
[0051] As shown in FIG. 3 , the three-dimensional material 25 preferably has a unique knit or weave configuration.
[0052] Such material 25 may include strands or lengths of polymer materials woven together. The material 25 may also include some fiberglass or carbon in addition to the polymer materials. Polynova, located in Milford, Mass., typically provides such materials and textiles for closed-mold interlaminar vacuum infusion processes. Preferably, the material 25 of the present invention is Polynova's Polybeam® or HIFLUXF90™ material. See www.polynovacomposites.com.
[0053] Preferred characteristics of these materials may be as follows:
Polybeam® 703 PET:
[0054] x,y fiber type: multi-filament polyester (PET)
z fiber type: mono-filament polyester (PET)
areal weight: 0.800 oz./ft.2
infused weight: 2.540 oz./ft.2
thickness: 0.026 inches
roll width: 60 inches std., to 160 inches
roll length: to suit
HIFLUX90™ PET:
[0055] x,y fiber type: high tenacity polyester
areal weight: 1.26 oz./ft.2
infused weight: 5.07 oz./ft.2
thickness: 0.056 inches
roll width: 60 inches std., to 160 inches
roll length: to suit.
[0056] Alternatively, instead of HIFLUX90™, the material 25 may be a continuous strand fiberglass that is looped upon itself. This material 25 is preferably an ACR glass Fiber Reinforced Plastic (FRP) mat available from Superior Fibers Inc. of Bremen, Ohio (see http://www.superiorfibers.com/).
[0057] Referring again to the drawings, FIG. 3 schematically illustrates a representative fabric material 25 in a free or uncompressed relaxed form. As shown, in this illustration of, e.g., HIFLUX90™, there is preferably a pair of outer, generally woven fabric layers, 22 and 24 , lying generally in the respective X-Y planes. Separating, and disposed between, these layers is a plurality of resilient fibers or yarns 26 lying generally in a “Z” direction. The Z direction fibers need not be at an exact 90-degree orientation, and generally are not. The angle is not critical and may vary substantially, for instance between about 30 degrees and 90 degrees. As indicated, the overall thickness dimension “d” of the fabric may be between about one or two mm up to about 25 or 30 mm, or even more, with presently preferred dimensions in the range of about two mm to about twelve mm.
[0058] As FIG. 3 also shows, the Z direction fibers preferably lie between the two outer layers 22 , 24 . These outer layers may range from an open honeycomb structure to a more tightly woven warp and weft structure.
[0059] FIG. 4 schematically represents how the three-dimensional fabric 25 compresses in the Z direction to a lesser thickness “d”. When, for example, it is sandwiched between, for example, fabric or felt layers 40 , 50 . Even though compressed, the three-dimensional fabric architecture facilitates hardening agent flow, penetration, and distribution throughout the structure including the surrounding and adjacent layers of the entire laminate lay-up. Moreover, when the fabric or felt layers are needle punched, the agent, e.g., liquid resin, will have a flow path such that it not only fills the intermediate spaces between fibers 26 of material 25 but also flows laterally so as to also fill and saturate both the outer layers 22 , 24 and also adjacent felt or fabric layers 40 , 50 .
[0060] In the past, the problem has been that resin must pass more incrementally as the required infusion distance is increased. Thus, “length losses” accumulate as resin travels ever more slowly through the flow medium while encountering approximately the same frequency of the fiber “obstacles”, which also serve as structural reinforcement. Thus, interlaminar infusion, or infusion from within the substrate or laminate, has achieved little adoption in the prior art despite being naturally advantageous as compared to surface infusion techniques like SCRIMP™, from cost, waste, and property-additive standpoints.
[0061] Interlaminar fabric material knit 25 according to this invention e.g., an added layer, can also be sandwiched and/or placed on either face of the fabric 40 , 50 to promote infusion on all sides of the dry laminate, which greatly speeds infusion. Furthermore, this interlaminar material can increase laminate thickness and also allow for better visual quality. The invention further overcomes such problems as incomplete or slow infusion, uneven distribution or pooling of resin, long set-up time, material waste, and weakened strength in the finished composite.
[0062] In one embodiment of this invention shown in FIG. 5 , the fabric material 25 is constructed of small diameter monofilament polyester, e.g., PET, in the Z plane and with fiberglass yarn, e.g., ECR, on the X/Y fascia planes as both are relatively well-known materials. These materials are preferably knitted together to form the material 25 . A reduced diameter and/or stiffness in the Z directional yarn or fiber may require reduced columnar height, and therefore a less free-form thickness of the fiber, to ensure adequate buckling yield and resilient spring-back behind the resin flow front. Despite the reduced free-form thickness, this embodiment may add the same overall thickness to the consolidated laminate as thicker free-form designs.
[0063] In another embodiment of this invention shown in FIG. 6 , a diamond-shaped woven architecture (instead of knitted) provides unique mechanical properties for the three-dimensional material or weave 25 because the fibers are oriented in a preferred direction for strength in the mat laminate 20 . The intent of this material is to reduce or eliminate the need for additional reinforcement materials in a given laminate and increase overall cost savings.
[0064] The invention also contemplates a fabric design for the material 25 , which presents another low-cost material. This product has a similar Z directional structure, but with smooth faces. The X/Y faces here are knitted with multifilament polyester thermoplastics, e.g., PET, with tight face architectures. Smooth faces may help mitigate surface profiling, also known as print. This embodiment also provides an opportunity to use low-cost recycled PET for the multifilament components.
[0065] The choice of fibers 37 , 37 a needle punched in Z direction, e.g., through the fabric 40 , 50 and material 25 , can be widely varied and the selection thereof is influenced by the mechanical characteristics of the fiber material. These fibers may generally be glass or carbon fibers, although standard carbon fibers are generally not preferred as resiliency and an appropriate bending modulus are the desired characteristics for this element. As indicated, the Z fibers act essentially as joining barbs and also create flow chutes from the outer fabric layers. Therefore, important factors to consider for this selection include a balanced combination of length, column (or denier), spacing and orientation relative to the outer layers. While deniers of fibers, percentage of glass fiber with respect to other materials, and finished product sizes may vary, the preferred glass content is about 40% by volume 50% by weight, the density is preferably less than one ounce per square yard to fifty-two ounces per square yard and about 1.8-2.2 ounces per square yard, and denier size is about 102-204 with an preferred size of 113. The preferred filament diameter would range about 0.00018-0.00025 with a preference of 0.00023. These have been found to provide sufficient strength and tenacity while maintaining invertibility.
[0066] The fiber architecture thereby achieved according to the present invention is optimal for resin infusion processing and can greatly enhance final performance-to-weight properties such as shear strength, rigidity and damage tolerance. A vast spectrum of physical property enhancements can be further tailored by designing X/Y/Z fiber architectures with hybrid combinations of polyester, glass, carbon, aramid, polyolefin, and/or other materials. The practice of this invention may also provide a relatively low-profile material.
[0067] FIG. 7 shows one embodiment of the present invention prior to inversion. In this embodiment, the first layer is a fabric or felt 40 . On top of the felt is the ECR fiberglass layer 35 . On top of the fiberglass layer 35 is the three-dimensional material 25 . Next, preferably is another felt layer 50 and then finally the coating or cover 60 .
[0068] In this embodiment as shown, there is preferably a top or bottom 22 , 24 missing from material 25 . Thus, small strands or barbs 25 a protrude from the material 25 and into felt layer 50 . This preferably occurs when the layers 25 , 35 , 40 , and 50 are sandwiched together by the compression process. The needling process preferably takes place before the coating 60 is added. During the needling process, a small needle (not shown) punches the layers and thus creates small channels 37 b in the layer 40 . As the needles penetrate through to the fiberglass layer 35 , some pieces of fiberglass 37 a are pushed into a perpendicular orientation. As shown, not all of the fiberglass fibers 37 are affected by the needling process as they remain in a more random orientation. It should also be noted that during the needling process some fibers 37 a are pushed into other layers such as the three-dimensional material layer 25 and the optional additional felt layer 50 . Although not shown, small channels are created by the needles as they pass through these additional layers 25 and 50 .
[0069] Once needling has taken place, the mat 20 may be rolled by a large roller for further compaction. This rolling and compaction process further pushes barbs 25 a and fiberglass fibers 37 a into the various layers 40 , 37 , 25 , and 50 . The needling may also occur through the second felt layer 50 from the side opposite the side closest to layer 40 . There, some fibers 37 c are pushed into first felt layer 40 . Of course, this may also occur during the compaction process so an additional needling staff may not be needed. Once the needling is complete coating or cover layer 60 is added. Preferably, this layer 60 is not punctured so that it acts as a resin catch when the tube is inverted. See, for example, FIGS. 2 and 8 .
[0070] As mentioned, the resin is preferably added by a pinch and roller process. This can be a separate step or may be part of the compaction process. The channels 37 b , perpendicularly orientation fibers 37 a , and three-dimensional material 25 all greatly enhanced the flow of resin through the felt layers 40 , 50 to totally saturate the entire mat 20 .
3. In Use and Operation
[0071] The member 10 of the present invention is preferably fabricated off-site from the actual place where the pipe is to be rehabilitated. At the fabrication site, the manufacture includes fabricating a glass-reinforced member or liner 10 by preferably laying down a sheet or layer of polyester felt or fabric 40 , a layer 35 of loose glass fibers 37 on top of the fabric 40 , and a sheet 25 of three-dimensional polyester strand and fiberglass yarn on top of the fibers. Another layer of fabric 50 may then be added on top of the sheet 25 . Then, the fabric and fibers are bonded (preferably by needling) to the sheet 25 to form a composite substrate or mat 20 . The substrate 20 is then formed into a tube. This is accomplished by connecting, joining, or bonding the edges of the substrate 20 , preferably, by an adhesive overlap. In other embodiments, flame joining or stitching may be used. The stitching may include, e.g., a prayer stitch with the edges forming a butt joint. Next, a resin is applied to the tube. A coating 60 may be added on the tube to retain the resin 65 in the tube.
[0072] At the rehabilitation site, the method of installation preferably includes inverting the tube into a pipe 70 to form a inside diameter liner 10 . FIG. 8 shows a perspective cutaway view of the tube or pipe 70 with the member 10 inserted therein. When the mat 20 soaked with resin 65 (not shown) is ready, the member 10 is inserted at the mouth of the pipe or tube 70 . A gas is then preferably used to invert the member 10 into the tube 70 . The tube preferably has its inner sidewalls completely covered with the member 10 . A light and a camera are then preferably inserted into the tube to ensure that the member 10 is affixed to the sidewalls of the tube 70 . Preferably, the member 10 does not have any wrinkles and no resin 65 is leaking, e.g., through cover 60 . After inversion, the coating 60 is now on the inside of the inverted tube member 10 . Another key with here is that liner dimpling is possible with thinner, more flexible liner. This is beneficial because when the liner is inspected with the camera, the operator can see the dimples with his camera. The operator will then know that such dimples likely indicate hook-ups to homes or other incoming pipe systems.
[0073] Once the member 10 is in place and has been inspected, the resin 65 is cured to harden the member 10 in place within pipe 70 . In one embodiment, an ultraviolet light cures the resin in the liner 10 form a hard inner shell within the pipe 70 . Alternatively, the liner 10 is cured with hot water or steam.
[0074] Once in place, the cured inner knit/weave structure of the liner 10 of the present invention provides 0 degrees, 45 degrees, 90 degrees x-y-z axis strength. Further, given the make-up of the inventive liner, pipe rehabilitation crews do not need as much material to rehab a pipe.
[0075] The present invention described herein provides improved tube strengthening. As illustrated in the Graph and Tables set forth below, the strength of inventive liner has been tested to show the following:
[0000]
TABLE 1
Load
Stress
Displacement
At Yield
At Yield
Strain
Flexural
At Yield
(Max
(Max
At Yield
Modulus
Width
Depth
(Max Load)
Load)
Load)
(Max
(AltYoung)
(in)
(in)
(in)
(lbf)
(psi)
Load)
(psi)
1
0.497
0.315
0.317
106.0
16524
0.023
969870
2
0.500
0.320
0.291
77.2
11584
0.021
809981
3
0.501
0.318
0.344
92.2
13992
0.025
923094
4
0.502
0.312
0.230
78.9
12420
0.016
1035449
5
0.500
0.338
0.249
74.6
10007
0.019
545798
Mean
0.500
0.321
0.286
85.8
12911
0.021
917438
S.D.
0.002
0.010
0.047
13.2
2474
0.003
97083
C.V.
0.374
3.178
16.440
15.4
19
15.772
10
[0000]
TABLE 2
Load
Flexural
Flexural
Width
Depth
Strain At
At Yield
Strength
Modulus
(in)
(in)
Yield
(lbf)
(psi)
(psi)
1
0.489
0.220
.0372
27.75
7035
480897
2
0.496
0.230
.0442
31.26
7148
448915
3
0.495
0.235
.0384
28.03
6152
419574
4
0.500
0.222
.0374
27.38
6667
435943
5
0.495
0.229
.0454
32.79
7579
439087
Mean
0.495
0.227
.0405
29.44
6916
444883
S.D.
0.004
0.006
.004
2.43
537
22734
[0076] In the Graph and Tables above, data from the 4900PN Sample (which is an embodiment of the present invention) and the Lam 2098 Sample (which is a resin and standard felt typical to the industry) is shown. The specimens graphed are different portions taken from the same panel. In reviewing the same, it is obvious that the mechanical properties are quite a bit different, e.g., the invention being stronger. Moreover, if you look at the graphs, the standard material has a smooth curve to failure while the inventive liner has a jagged edge before it fails. Further, although it is smooth at the beginning, it is thought that the configuration of the inventive liner is transferring its load on all three axis's before total failure can occur, resulting in a more robust liner. In other liners, the materials are constructed on the (x, y) plane while the arcs on the graph still have a smooth transition to fail, there might be some jagged areas. However, these do not appear as profound as the inventive liner.
[0077] Certain preferred steps have been found in testing the liner. For example, in one preferred embodiment, the PET fiber used in the mat is preferably not coated as it typically is with a fatty acid ester coating. The fatty acid ester coating causes problems with the joining of the substrate or laminate and, thus, if it is added, the laminate may not be properly formed.
[0078] It has also been found that the cover and other layers which make up the laminate must be free of any debris or other foreign particles such as dust or dirt, which might prohibit the proper joining of the layers of the laminate. Such debris and other foreign materials might also affect the liner's ability to pass potable water testing certifications. It is also important to ensure that the needling of the various layers is done to the proper density. Such needling allows for proper formation of a tightly configured laminate. Further, when the layers, such as the fabric, are run through cutting and slitting operations, it is important that the tensioning on the fabric is appropriate. This proper tension may be applied by having a tension applied to the full length of the roll of fabric. If improper tension is applied to the fabric or another layer, strands of fiber may be inadvertently stretched or torn which would cause the fabric to loose some of its strength and/or become “open faced”. In some applications, this might be desirable because it may lead to better joining between the fiber layers. However, in other applications where strength is necessary to ensure proper burst pressure of the liner once it is in place for high-pressure applications, broken or stretched strands would be highly undesirable. Thus, as can be seen, it is important to maintain proper quality control measures in laminate manufacture depending on the end user application of the liner.
[0079] There are virtually innumerable uses for the present invention, all of which need not be detailed here. All the disclosed embodiments can be practiced without undue experimentation.
[0080] Although the best mode contemplated by the inventors of carrying out the present invention is disclosed above, practice of the present invention is not limited thereto. It will be manifest that various additions, modifications and rearrangements of the features of the present invention may be made without deviating from the spirit and scope of the underlying inventive concept.
[0081] Moreover, the individual components disclosed herein need not be formed in the disclosed shapes, or assembled in the disclosed configuration, but could be provided in virtually any shape, and assembled in virtually any configuration. Further, although each layer of the liner is described herein as physically separate, it will be manifest that the may be integrated into the layer with which it is associated. Furthermore, all the disclosed features of each disclosed embodiment can be combined with, or substituted for, the disclosed features of every other disclosed embodiment except where such features are mutually exclusive.
[0082] It is intended that the appended claims cover all such additions, modifications, and rearrangements. Expedient embodiments of the present invention are differentiated by the appended claims.
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A material composition and method for making flexible inversion liners having glass fibers added for strength is disclosed. The liner combines a first layer of polyester felt, an open-faced knit of fabric from ECR glass and PET strands, glass fibers, and a second layer of polyester felt. These components are needle-punched together into essentially a single composite mat, or substrate, using standard needle-punching machinery. The liner is then formed into a tube preferably through a butt joint and prayer stitch covered with a urethane tape. A coating or foil is placed on the outside (prior to inversion) of the liner that is then impregnated with resin. For heat curing, the liner is impregnated with a thermosetting or UV-cured resin. The liner is then installed in a pipe through inversion, using either air or water and cured with UV, steam, or hot water.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of snowmobiles.
2. Description of the Prior Art
Snowmobiles are vehicles that are constructed to travel across snow and ice. As is generally known, the snowmobile is driven by an endless drive track arranged at the rear end of the underside of the snowmobile. The front end of the snowmobile is supported by, and rides along, two skis, which glide across the surface of the snow or ice. Typically, the skis have carbide inserts that run along a portion of the bottom surface of the ski runner and aid in the steering of the snowmobile.
A disadvantage of snowmobiles is that, when taken out of the their designed snow environment, they become quite difficult to transport because the skis and track drive do not readily glide along the surface when traveling across gravel, hardtop, or other non-snow surfaces. Therefore, even the most trivial of movements, such as, moving from one side of the garage to the other, requires a tremendous amount of effort and strength, because the snowmobile must repeatedly be lifted and dragged to its desired location. Often the owner resorts to alternating lifting and dragging the front of the snowmobile a few inches, then switches to lifting and dragging the back end to catch up with the front. It is easy to see understand that moving a snowmobile is difficult for riders who are not physically very strong, and is, at best, rather strenuous for even those riders who have a great deal of physical strength.
Such challenges are not limited to moving a snowmobile around a driveway or garage. Loading and unloading the snowmobile onto a flat-bed or a trailer, a common task for most snowmobile riders, presents another physically challenging task, even for the strongest of riders. Although the track drive can provide some of the moving power, the snowmobile is not at all steerable on non-snow surfaces and still needs to be guided by the operators to ensure that it travels in the desired direction. Normally two riders team up to guide and/or push the snowmobile in the desired direction—one rider mounts the snowmobile and operates the throttle, and the other pushes and guides the snowmobile. This cooperative effort is potentially extremely hazardous to the person guiding the snowmobile, as an unexpected fluctuation in the throttle can cause the snowmobile to lurch or jump, presenting the potential of severely injuring that person if he or she is in the path of the lurching snowmobile.
Not only is snowmobile movement on non-snow surfaces difficult, such movement is potentially damaging to the snowmobile as well. For example, driving or dragging a snowmobile across a non-snow surface subjects the track and the carbide tips on the skis to excessive wear and, as a result, they may require more frequent replacement.
Lack of accessibility to the lower portions of the machine, such as the drive track, can also present a difficulty to the rider. For example, to make adjustments to the drive track, the back end of the snowmobile must be propped up off the ground to allow free track movement. Typically, this is achieved in the shop by propping it up on cinder blocks, bricks, or resting it on a jack. This solution is inadequate for reasons of safety and convenience. For example, propping a snowmobile up on blocks is unsafe as it may fall over if jostled. Additionally, the rider who needs to make adjustments while out for a ride, generally does not have blocks or a jack available to support the snowmobile in a raised position.
What is needed, therefore, is apparatus for securing a snowmobile in an upright position, with the rear end of the snowmobile raised above the ground. What is further needed is such apparatus that is easily operable without requiring a great deal of physical strength. What is yet further needed is such apparatus that will allow the vehicle to be maneuvered easily over a surface that is not snow or ice. What is still yet further needed is such apparatus that will improve the steerability of a snowmobile while it is being maneuvered across a surface that is not snow or ice.
SUMMARY OF THE INVENTION
For the reasons cited above, it is an object of the present invention to provide apparatus that will secure a snowmobile in an upright position, with the rear end of the snowmobile raised above the ground. It is a further object to provide such apparatus that is easily operable by a single person, without requiring great physical strength. It is a yet further object to provide such apparatus that allows a single person to easily steer a snowmobile while maneuvering it across a surface that is not snow and/or ice.
The objects of the present invention have been achieved by providing a support stand, that is, a center stand or kick-stand, that is attached to the rear end of a snowmobile and is easily deployable. The support stand according to the invention is a collapsible support that is mounted on the rear end of the snowmobile and that, when deployed, provides a rigid support that lifts and supports the weight of the rear end of the snowmobile. The support stand may be equipped with a rolling means that allows the rear end of the snowmobile to roll along a floor or ground surface. The support stand also comprises a deployment mechanism for deploying and locking the stand into the deployed position, and, when stowed, for securing the stand in a stowed position.
In a first embodiment, a support stand comprises side arms that are attached to each side of the chassis of the snowmobile. The side arms are pivotable between a locked, deployed position and a stowed position. In the stowed position, the side arms are raised up off the ground and secured in place; in the deployed position, the side arms are dropped down and locked into a position that raises and supports the rear end of the snowmobile above the ground. If the support stand is equipped with a rolling means, deployment places the rolling means in contact with the ground surface, thereby allowing the rear end of the snowmobile to roll along the ground surface. In this first embodiment, a connecting bar or crossbar connects the lower ends of the side arms. The attachment and deployment mechanism comprises a pair of pivotable rails, one rail being attached to a respective side arm by means of a pin. The rail has a curved slot that includes a catch. When being deployed, the pin moves in the curved slot until it is caught in the catch. To secure the support stand in the stowed position, the crossbar is lifted up off the ground and secured in the stowed position by means of a cord or a latch mechanism.
In a second embodiment of the support stand according to the invention, the stand comprises two leg assemblies that are mounted at an upper end directly onto the chassis, one assembly on each side of the chassis. Each leg assembly includes a leg that is pivotable such that the lower end of the respective leg drops to the ground surface and is locked into a deployed position. The support stand may be equipped with a wheel, to provide a support stand that is rollable. The wheel is mounted at the lower end of the leg.
The attachment and deployment mechanism comprises a rail that is mounted on the chassis, along the side at the rear end of the snowmobile. The rail has a slot with a catch. The leg is linked to the rail by a pin that slides in the slot and that catches in the catch when the leg drops down into deployment position. Ideally, the leg assemblies are ganged together with a connecting bar at or near the upper end of the respective legs, so that the attachment and deployment means deploy both legs simultaneously.
The support stand according to the invention is retrofittable onto conventional snowmobiles. In such a case, the support stand assembly includes a mounting plate and/or brackets as required to attach the support stand to the chassis of the snowmobile. Also included within the scope of the invention is a support stand that is provided on a snowmobile as an integral part of the snowmobile construction. For example, the support stand may be provided as an option for a snowmobile that is equipped with a support stand mount for receiving the center stand assembly, or the support stand may be provided as a standard component of a snowmobile. In this case, the chassis of the snowmobile may include a well in which to stow the support stand when it is not deployed, and a mounting system and deployment means that is built into the walls of the well.
If the skis on the snowmobile are also equipped with wheels, the support stand with wheel now allows the snowmobile to glide easily and steerably across a non-snow, non-ice surface. Suitable ski wheels are disclosed in U.S. patent application Ser. No. 09/818,058, filed by the applicant of the present invention on Mar. 26, 2001, and which is incorporated herein by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the first embodiment of the support stand according to the present invention.
FIG. 2 is an elevational view of a snowmobile equipped with convertible skis with wheels and the support stand according to the present invention, the support stand and the wheels on the skis being in respective non-deployed positions.
FIG. 3 shows the mounting bracket and the deployment link of the present invention.
FIG. 4 is an elevational view of the snowmobile of FIG. 2 , with the support stand and the ski wheels being in fully deployed position.
FIG. 5 is a partial view of the snowmobile of FIG. 2 , equipped with the support stand according to the invention, the support stand having a fluid-pressure actuating means.
FIG. 6 is a perspective view of the second embodiment of the support stand according to the invention.
FIG. 7 is an elevational view of the support stand of FIG. 6 , illustrating the assembly of the side arm with braces, the connecting bar, and the run of the deployment cable.
FIG. 8 is a perspective view of the rail and mounting plate of the support stand of FIG. 6 , showing the side arm in deployed position.
FIG. 9 is a planar view of the rail and mounting plate of FIG. 8 , showing the side arm and wheel in the stowed position.
FIG. 10 is a perspective view of the rear end of a snowmobile with the support stand of FIG. 6 mounted onto the chassis and deployed.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is an illustration of a first embodiment of a support stand 1 according to the present invention. The support stand 1 of this particular embodiment comprises a frame 3 and a rolling mechanism 10 . Although in the description of this embodiment that follows, the rolling mechanism 10 is described, it should be understood that it is possible to provide the support stand 1 without a rolling mechanism. In that case, the support stand 1 becomes a stationary support stand that lifts the rear end of a snowmobile 101 above a ground surface G, but does not promote easy rollability of the snowmobile 101 . The frame 3 in the embodiment shown includes a crossbar 2 and two side arms 4 . At the distal end of each side arm 4 is an attachment and deployment means 6 by which the support stand 1 is pivotably attached to the body of a conventional snowmobile. Other embodiments of the frame 3 may be U-shaped or otherwise contoured so that the frame 3 is connectable to the body of a snowmobile in a way that does not hinder or interfere with the conventional operations of the snowmobile. In the particular embodiment shown in FIG. 1 , the attachment and deployment means 6 includes a mounting bracket 16 and a deployment link 8 that is pivotably attached to the respective mounting bracket 16 at one end and to the side arm 4 at the other end. The rolling mechanism 10 is mounted on the crossbar 2 . In the embodiment shown, the rolling mechanism 10 is a wheel. It is, of course, possible to mount more than one wheel on the crossbar 2 or to use some other suitable type of rolling mechanism 10 other than the wheel, such as a track with roller balls, or one or more rollers made of round stock that are assembled on the crossbar.
FIG. 2 shows the support stand 1 mounted on a conventional snowmobile 101 and secured in a stowed position by a retainer 18 . The retainer 18 shown in this embodiment is a simple strap, but it should be understood that any suitable means for securing the support stand 1 can be used, such as a mechanical or electro-mechanical latch, a magnetic or electro-magnetic latch, a hasp and staple, etc. Also shown on the snowmobile 101 is a convertible ski 30 that has a ski-wheel 32 deployably attached to it. This convertible ski 30 is the subject of U.S. patent application Ser. No. 09/818,058, commonly owned by the inventor of the present invention. As shown in FIG. 2 , the ski-wheel 32 is raised above the ground in a non-deployed position.
FIG. 3 illustrates the attachment and deployment mechanism 6 for securing the support stand 1 in a deployed position. The deployment link 8 is pivotably attached to the mounting bracket 16 and slidably attached to the side arm 4 by a pin 9 . The deployment link 8 has a groove 14 that has a catch 8 A that restrains the pin 9 from sliding in the groove 14 , thereby securing the side arm 4 in the deployed position. FIG. 1 shows the support stand fully deployed, with the pin 9 restrained in the catch 8 A; FIG. 3 shows the support stand before it is deployed, with the pin 9 able to slide in the groove 14 . The mounting bracket 16 is securely affixed to each side of the conventional snowmobile 101 such that the support stand 1 , when in the stowed position, is in the vicinity of a bumper B that is conventionally mounted on the snowmobile 101 . A deployment cable 12 is connected to the deployment link 8 attached to the mounting bracket 16 on one side of the support stand 1 to the mounting bracket 16 on the other side of the support stand 1 . For the sake of clarity, a mudflap that is typically attached to the snowmobile 101 beneath the bumper B is not shown.
To release the support stand 1 from the stowed position shown in FIG. 2 to a deployed position shown in FIG. 4 , one pulls the retainer 18 . In the embodiment shown in the FIGS. 2 and 4 , the deployment link 8 pivots downward and the support stand 1 simply drops to the ground by force of gravity. By lifting slightly on the rear bumper of the snowmobile 101 , the support stand 1 rolls under the snowmobile 101 and the pin 9 snaps into the catch 8 A and holds the support stand 1 in the fully deployed position under the rear end of the snowmobile 101 . FIG. 4 shows the snowmobile 101 , equipped with the support stand 1 according to the present invention, and the convertible skis 30 with wheels 32 . As shown, the rear end of the snowmobile is raised above ground level and supported on the rolling mechanism 10 when the support stand 1 is deployed. If the wheels 32 on the convertible skis 30 are deployed as well, the front end of the snowmobile 101 is also raised above ground level. In this position, the snowmobile 101 can be maneuvered easily across a surface that is neither snow nor ice. In addition, if the rolling mechanism 10 is a wheel that is swivel-mounted or roller balls that allow rotation in any direction, the snowmobile 101 can also be steered as it is pushed or pulled in a backward direction.
FIG. 5 illustrates another embodiment of the invention in which the deployment means 6 is a drive means 34 that drives the frame 3 into a deployed position as well as to a stowed position. The drive means 34 includes a cylinder 24 and a piston 26 . As shown, the cylinder 24 is mounted on a side arm 4 of the frame and the operating end of the piston 26 is attached to the mounting block 16 so as to drive the frame 3 to a stowed position (shown with dotted lines) from a deployed position and vice versa. Fluid-pressure drive means such as the piston and cylinder drive means 34 shown in FIG. 5 are generally well-known and the details of such means and their means of actuation are neither discussed nor shown herein. It is within the scope of the invention, however, that such drive means 34 may be driven by any suitable pressurized fluid system, such as air or hydraulic fluid.
FIGS. 6-10 illustrate a second embodiment of the support stand 100 according to the invention. FIG. 6 is a perspective view and FIG. 7 a frontal (elevetional) view, showing the support stand 100 in its deployed position. As best shown in FIG. 7 , the support stand 100 comprises two essentially identical leg assemblies 121 , each of the assemblies ganged together by a ganging bar 128 . In the embodiment shown, each leg assembly 121 comprises a support leg 120 with a wheel 124 mounted at the lower end and a deployment mechanism 108 . The deployment mechanism 108 includes a means of allowing the leg assembly 121 to drop from a stowed position, illustrated in FIG. 9 , to a deployment position, shown in FIG. 6 . In this second embodiment, the deployment mechanism 108 comprises a pair of rails, 104 and 106 , each rail having a groove 109 for slidably receiving a pin 109 A. The pin 109 A pivotably links the upper end of the leg 120 to the two rails, 104 , 106 . A catch or locking slot 110 is provided in one end of the groove 109 in which the pin 109 A catches when the leg 120 is allowed to drop, and looks the leg 120 into a deployed position. In FIG 6 , for purposes of illustration, the pin 109 A is shown just before it drops down into the locking slot 110 .
In this second embodiment, the support stand 100 is designed to be retrofitted onto a conventional snowmobile 101 and one of the rails, a first rail 104 , serves a dual function. Not only does it serve as part of the deployment mechanism 108 , but also as as a mounting bracket to mount the support stand 100 to the chassis of the snowmobile 101 . As shown in FIG. 6 , the first rail 104 has a contour that fits a conventional snowmobile. A portion 104 A of the rail 104 extends downward sufficiently to provide a convenient location for mounting the ganging bar 128 without interfering with the operation of the snowmobile or the support stand. A plate 112 is provided on the first rail 104 to accommodate a bogey wheel on the snowmobile.
The legs 120 are braced with braces 122 . In the embodiment shown, an upper end of a first brace 122 is pivotably attached to the first rail 104 and an upper end of a second brace 122 is attached to the second rail 106 ; the lower ends of the braces 122 are pivotably attached to the respective legs 120 as shown in FIGS. 6 and 7 . The leg assembly 121 further comprises assembly spacer bars 111 which hold the first rail 104 and the second rail 106 a distance apart to accommodate the width of the leg 120 and bushings.
FIG. 8 illustrates a leg assembly 121 A that is used on a snowmobile having a chassis that is constructed to receive or hold the support stand 100 according to the invention. In this case, the first rail 104 is essentially identical to the second rail 106 , and is mounted on a mount provided on the chassis.
FIG. 9 shows the leg assembly 121 with the leg 120 retracted in a stowed position. Also shown in this view is a bracket 130 that is used to provide an additional attaching point to the chassis of the snowmobile 101 .
FIG. 10 is a perspective illustration of the second embodiment of the support stand 100 according to the invention, mounted on a conventional snowmobile 101 . Only one side of the rear end of the snowmobile 101 is shown, and that with only sufficient detail to properly illustrate the mounting of the support stand 100 on the snowmobile 101 . As shown, the leg assembly 121 is attached to the chassis of the snowmobile 101 , one assembly on each side of the snowmobile 101 . The ganging bar 128 connects the two leg assemblies 121 and is shown in this illustration extended from the one leg assembly 121 through the chassis of the snowmobile. The bracket 130 , mentioned earlier, is attached to the bottom surface of a horizontally extending panel on the chassis. Whether this bracket 130 is necessary depends on the specific geometry of the conventional snowmobile and it should be understood it is within the scope of the present invention to use one or more brackets as required to fasten the support stand 100 to the conventional snowmobile.
The support stand 100 according to the invention also includes an actuation mechanism 140 , which, in this case, is a spring-biased tension cord 141 that extends around the bumper of the conventional snowmobile and is attached to each leg 120 of the support stand 100 . As shown in FIG. 10 , the tension cord 141 feeds into the leg assembly 121 through assembly spacer bars 111 A and 111 b, runs down to a lower assembly spacer bar 111 C, and then up to the upper end of the leg 120 where it is attached. By pulling on the tension cord 141 , ideally while lifting the rear end of the snowmobile 101 at the same time, the pin 109 A is moved from the locking slot 110 up into the guide groove 109 , allowing the leg assembly to be folded to stowed position. Other actuating mechanisms as described above in conjunction with the first embodiment of the support stand 1 are also applicable to this second embodiment. Such actuating mechanisms include pressurized fluid systems, such as a pneumatically driven piston and cylinder unit. For example, with such an actuating mechanism, one end of the piston is connected to the leg 120 and the other captured in a cylinder that is mounted on the chassis of the snowmobile 101 or on a bracket or rail of the support stand 100 .
The illustration of the second embodiment shows the support stand 100 having a wheel 124 at the lower end of each leg 120 . It is within the scope of the invention to provide the support stand 100 without the wheels mounted on the legs. The support stand 100 is then a stationary support stand that raises the rear end of the snowmobile above the ground surface G.
The embodiments described herein are merely illustrative of the present invention. It should be understood that variations in construction 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 support stand for supporting the rear-end of a snowmobile above the ground. The apparatus may be fitted with rollers or wheels in order to improve the maneuverability of the snowmobile when it is being transported across a non-snow or non-ice surface.
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FIELD OF THE INVENTION
The present invention generally relates to the transportation of a cryogenic liquid such as LNG. More particularly, the present invention relates to a system and a method by which a gas provided by the evaporation of a portion of the cryogenic liquid is transferred, in a sound operating manner and in compliance with all governing international regulations, from the storage tank(s) of a land or marine vehicle for the purpose of being used as fuel by the gas-burning engines of the another land or marine vehicle.
BACKGROUND OF THE INVENTION
Natural gas, when cooled to approximately −260° F., changes phase from a gas to a liquid, thus “Liquefied Natural Gas” or “LNG.” In this phase change process, the volume required to hold a specific quantity of natural gas is reduced by approximately 600 times, thus making it possible to transport significant, and economic quantities of natural gas over great distances from source to market.
LNG is a boiling cryogen that is usually stored at atmospheric temperature and pressure equilibrium conditions. Unlike other gaseous fuels such as propane and butane, which can be stored as a liquid at atmospheric temperatures by allowing the liquid and the gas in the tank to reach a stable equilibrium vapor pressure for any given atmospheric temperature, LNG (the principal component of which is methane) cannot be maintained as a liquid under pressure at atmospheric temperatures due to its low critical point pressure (673+ psia for methane), critical point temperature (−115.8° F. for methane), and very high vapor pressures. Accordingly, LNG is stored and is transported in heavily insulated tanks.
Although the amount of heat that reaches the LNG is significantly reduced by the tank insulation, the heat inflow to the LNG cannot be entirely eliminated. Consequently, a quantity of cold natural gas vapor (referred to as “boil off vapor” or “boil off”) is constantly being generated and must be removed from the tank and must be either disposed of or re-liquefied in order to prevent an overpressure condition of the LNG tank. Specifically, the resulting boil off is either: (1) vented to the atmosphere (which venting is limited, by regulation, as an emergency/extraordinary procedure because natural gas is flammable and is a significant greenhouse gas); (2) heated, pressurized, and sent to a gas distribution system (in the case of land-based LNG tanks); (3) re-liquefied and returned to the tank as LNG; (4) flared as waste gas; (5) burned in propulsion machinery as fuel (in the case of liquefied natural gas carriers, or “LNGCs”); or (6) contained in the LNG tank for a finite period of time by allowing the vapor space of the tank to increase in pressure as the LNG continues to boil. This latter option can only be sustained for a relatively short period of time, typically limited to days (generally less than a month).
Historically, LNG has been utilized to effect the transportation of natural gas from sources in remote regions of the world to end users in population centers where demand for energy, particularly natural gas, is continually increasing. LNG has also been utilized for the purpose of efficiently storing natural gas during periods of low natural gas demand for later use during periods of high natural gas demand, i.e., so called “peak shaving” operations.
Recently, LNG is increasingly being utilized as a feedstock for generating and industrial facilities and as a transportation fuel for both land and marine vehicles. Natural gas is an attractive transportation fuel from the perspectives of long term availability, reduced emissions, and cost advantage over traditional distillate fuels. However, to achieve an equivalent energy level, the size of the space needed to house the required quantity of LNG is substantially greater than the size of the space needed to house the required quantity of a light distillate fuel, such as diesel fuel.
The increased demand for and use of LNG is creating a need for additional waterborne strategies for transportation of LNG to end-user distribution facilities. The marine transportation and distribution of LNG, whether in inland rivers and waterways or on open ocean coastal routes, is often most efficiently and economically accomplished by systems that utilize tugboats and barges.
In the case of the only LNG barge to be built (see Donald W. Oakley, World's First Commercial LNG Barge , O CEAN I NDUSTRY , November 1973, at 29-32), the LNG boil off was allowed to accumulate in the LNG tank by allowing the pressure in the tank to increase over time. The LNG tanks and the insulation system were designed to contain the boil off for a period of 45 days before the LNG tank relief valves would open due to overpressure, thus releasing the natural gas to the atmosphere.
A significant problem with this approach is that the LNG itself will rise in temperature to reach the equilibrium temperature that corresponds to the pressure of the LNG tank. Specifically, as the LNG tank pressure rises, the LNG temperature will also rise. If this warm LNG is then pumped into an LNG storage tank that is at a lower/normal pressure (i.e., a pressure that is slightly above atmospheric pressure, e.g., approximately +100 millibars), the warm LNG will rapidly vaporize and will release large volumes of cold natural gas as the LNG is cooled by evaporative processes until the LNG again reaches an equilibrium temperature that corresponds to the new tank pressure. This is unacceptable, since an LNG receiving terminal will be unable to dispose of the excess natural gas and tank overpressure is likely, with subsequent release of natural gas to the atmosphere. Even a slightly warmer LNG can be problematic due to the phenomenon of “roll-over” within the storage tank resulting in rapid and uncontrolled LNG vaporization.
There is also an increased safety risk associated with LNG at equilibrium conditions that are above atmospheric pressure should the LNG be accidentally released. At higher pressure equilibrium conditions, the LNG will vaporize at an increased rate, thereby significantly increasing thermal radiation risks should the vapor cloud ignite prior to dispersing.
Self-propelled LNGCs use the boil off as propulsion fuel in the ship's engines and are, therefore, able to maintain proper LNG tank pressure and LNG temperature. In the case of a barge, however, this approach is not an option because a barge does not have propulsion engines.
The LNG barge referred to above solved this problem of the increasing LNG temperature with time by cooling the LNG in a controlled fashion during the discharge operation, prior to the LNG being pumped into land-based tanks. This process was described by Mr. Oakley in the November 1973 O CEAN I NDUSTRY article and will not be repeated herein. Such cooling process, depending on the length of time that the LNG is aboard the barge and other factors, can result in discharge delays and considerable additional expense. It also significantly complicates the discharging operation. Finally, the added LNG cooling equipment that is required is costly to purchase and is expensive to maintain.
U.S. Pat. No. 7,047,899 to Laurilehto et al. teaches the concept of using electric generator sets that are fitted to a barge and use natural gas as fuel, thereby allowing cargo tank boil off to be consumed in the engines, thereby allowing for control of the pressure of the cargo tanks. Electrical propulsion power for a tugboat is transferred to the tugboat from the barge by electrical cables. U.S. Patent Application Publication No. 2006/0053806 to Van Tassel also teaches several approaches for effectively managing LNG cargo tank boil off and, therefore, LNG cargo tank pressure.
An article entitled LNG - Power Is the Time Now? published in the February 2011 issue of M ARINE N EWS , teaches the concept of using an LNG fuel barge combined with a typical inland towboat to provide natural gas fuel to the towboat as there is generally insufficient space on the towboat to house a sufficient quantity of LNG fuel. This article describes transferring LNG to the towboat in liquid, cryogenic form and processing and re-gasifying the liquid gas on the towboat, so that the engines of the towboat can make use of the gas as fuel. Such transfer of cryogenic gas is extremely hazardous owing to both the cryogenic temperatures involved and the increased likelihood and consequences of leakage.
FIG. 5 of U.S. Pat. No. 2,795,937 to Sattler et al. (“Sattler”) discloses the transfer of the boil off gas from cargo tanks on a barge to a tugboat that tows (in this case, pulls) the barge. In FIG. 5, Sattler discloses that the boil off gas is to be transferred from the barge to the tugboat through a flexible conduit or pipe. The boil off gas is then to be used as fuel in the tugboat's propulsion power plant, in this case a steam boiler, in much the same manner as in a self-propelled ship (e.g., a LNGC). By consuming the boil off in the tugboat's propulsion system, the LNG cargo tank pressure can, therefore, be maintained at near atmospheric pressure.
An examination of Sattler reveals, however, that Sattler fails to recognize the many significant technical, operational, and regulatory problems that would prevent the embodiment shown in FIG. 5 from ever becoming operative. (In fact, to the best of the inventor's extensive knowledge of this field, such an embodiment has never been reduced to practice.) The most significant of these problems is the high likelihood that the flexible conduit or pipe would be damaged or severed by the unrestricted relative motion and resulting forces between the barge and tugboat, which is further aggravated by the typical distances (often in excess of 600 feet) that a barge is towed behind a tugboat. As a consequence, natural gas would be released to the atmosphere, creating a potentially hazardous situation due to the release of significant quantities of natural gas. At a minimum, this will contribute adversely to greenhouse gas emissions. Additional problems that Sattler fails to recognize include: (1) the flexible conduit or pipe would have to be able to accommodate motion in all degrees of freedom, as a tugboat and barge have complete freedom of motion relative to each other; (2) natural gas would be released to the atmosphere when connecting and disconnecting the flexible conduit or pipe; (3) you would have to find a way of purging the flexible conduit or pipe with inert gas prior to connecting or disconnecting the flexible conduit or pipe; (4) there does not appear to be any provision for emergency breakaway and disconnection of the flexible conduit or pipe should the tugboat need to separate from the barge or should the towline part, which is not uncommon; (5) there does not appear to be any provision for secondary containment of natural gas should the flexible conduit or pipe fail or leak; (6) there does not appear to be any provision to detect the leakage of natural gas should the flexible conduit or pipe develop a leak, or to detect leakage at the connections of the flexible conduit or pipe; and (7) there is no automatic shutdown of the natural gas transfer from the barge to the tugboat upon failure or leakage of the flexible conduit or pipe or its connections.
SUMMARY OF THE INVENTION
It has now been found that the foregoing problems are solved in the form of several separate, but related, aspects. A flexible gas transfer assembly is connected using connectors that incorporate self-closing valves in both halves of the connectors, so that natural gas fuel is contained within the gas transfer assembly when the assembly is disconnected, thereby eliminating the need to purge the gas transfer assembly with inert gas prior to disconnecting it. Additionally, little to no natural gas fuel is released to the atmosphere due to the self-sealing nature of the connectors.
In exemplary embodiments, an emergency breakaway connector separates the gas transfer assembly from either a tugboat or a barge, depending on the particular configuration, should the gas transfer assembly be subject to an excess axial load. (The emergency breakaway connector is designed to separate at a specific load.) Thus, if the tugboat is required to release from the barge in an emergency situation, the coupler pins that connect the tugboat to the barge are retracted, and the tugboat backs out of the barge notch. The axial load placed on the fuel gas transfer assembly as a result of the tugboat exiting the notch causes the emergency breakaway coupling halves to separate, thereby disconnecting the gas transfer assembly and allowing the tugboat to freely exit the barge notch. The emergency breakaway connector also incorporates self-closing valves, trapping any natural gas in the gas transfer assembly and preventing release of natural gas.
The gas transfer assembly includes a flexible inner transfer hose and a flexible outer jacket that envelops the inner transfer hose. The jacket space between the inner transfer hose and the outer jacket is purged and pressurized with a gas that will not support combustion, i.e., an inert gas. The jacket space is maintained at a pressure that is above the maximum pressure of the natural gas fuel in the inner transfer hose. If the inner transfer hose develops a leak, the higher pressure inert gas in the jacket space will leak into the inner transfer hose that carries the natural gas fuel. This leakage will result in a drop in the pressure in the jacket space, which will in turn cause a pressure switch to trip, thus providing an alarm and a shutdown signal that secure the transfer of the natural gas fuel in a safe manner. Likewise, a leak in the outer jacket will cause the inert gas to leak out, thereby causing a drop in the pressure in the jacket space and also causing a system shutdown. In this manner, any failure of the gas transfer assembly will result in the flow of natural gas fuel being shut down automatically.
Another potential source of natural gas leakage is the connectors, both the normal quick connect/disconnect connectors and the emergency breakaway connectors, that are used to couple the gas transfer assembly to the tugboat and to the barge. Since natural gas is lighter than air at ambient temperature conditions, leakage of natural gas at the connectors can be detected by placing hoods or shields over the connectors and fitting the hoods or shields with gas detector sensors. Even minor leakages of natural gas that would be undetectable by other means will be detected by the gas detectors and will cause alarms and system shutdowns. The likelihood of a natural gas leak going undetected and creating a safety issue on the tugboat or the barge is, therefore, reduced to acceptable and manageable levels consistent with the guiding concepts and principles of the governing international regulations for these types of vessels.
In accordance with the embodiments of the invention described below, natural gas at ambient temperatures can be transferred from a barge to a tugboat in an extremely safe manner. In such application, the fuel barge with LNG tanks is also fitted with the necessary processing equipment to re-gasify the LNG and heat the resulting natural gas to ambient conditions.
Although the presently preferred embodiments of the present invention described below are directed to the transfer of natural gas from a barge to a tugboat, the present invention is not to be understood as being limited to marine vessels. It should be understood that the present invention applies to any type of vehicle, including but not limited to marine vessels and land vehicles (e.g., railroad locomotives, railroad cars, and trucks).
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description and upon reference to the accompanying drawings, in which:
FIG. 1 is a profile view of an exemplary articulated tug/barge (“AT/B”) liquefied natural gas carrier (“LNGC”).
FIG. 2 is a plan view of the AT/B LNGC shown in FIG. 1 .
FIG. 3 shows an embodiment in accordance with the present invention.
FIG. 4 shows another embodiment in accordance with the present invention.
FIG. 5 shows an embodiment in accordance with the present invention used in connection with an AT/B vessel in which the tug is pitched at zero degrees in relation to the level trim of the barge.
FIG. 5A shows an embodiment in accordance with the present invention used in connection with an AT/B vessel in which the tug is pitched at an extreme aft pitch in relation to the level trim of the barge.
FIG. 5B shows an embodiment in accordance with the present invention used in connection with an AT/B vessel in which the tug is pitched at an extreme forward pitch in relation to the level trim of the barge.
FIG. 6 shows detail of the limits of motion of a natural gas flexible hose in accordance with the present invention.
FIG. 7 shows an exemplary embodiment in accordance with the present invention in the context of an arrangement of an inland towboat and a natural gas fuel barge.
FIG. 8 shows another exemplary embodiment in accordance with the present invention in the context of an arrangement of a railroad locomotive and a natural gas fuel tender car.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Definitions of certain terms used in this specification are as follows:
Vehicle—any means in or by which something is carried or conveyed; a means of conveyance or transport. As used herein, the term “vehicle” includes but is not limited to marine vessels (e.g., ships, tugboats, towboats, barges, and articulated tug/barges (“AT/Bs”)) and land vehicles (e.g., railroad locomotives, railroad cars, and trucks).
Self-propelled vessel—a marine vessel that possesses permanently installed capability to propel itself at sea, i.e., a “ship.”
Non-self-propelled vessel—a marine vessel that is without a permanently installed capability to propel itself at sea, i.e., a “barge.” A “self-propelled” vessel that, for whatever reason, is not using its installed capability for propulsion is not, as defined herein, a “non-self-propelled” vessel.
LNG—liquefied natural gas.
LNGC—a self-propelled LNG carrier of ship form.
LNG Barge—a non-self-propelled LNG carrier.
AT/B—a vessel arranged in an articulated tug/barge configuration, wherein propulsion of a non-self-propelled barge is provided by a separate tugboat that is connected to the barge by a pinned connection(s) that restrict motion in all degrees of freedom except for pitch.
AT/B LNGC—an LNG carrier arranged in an articulated tug/barge (AT/B) configuration, wherein propulsion of the barge is provided by a separate tug that is connected to the barge by a pinned connection(s) that restrict motion in all degrees of freedom except for pitch.
Towboat—an inland river vessel arranged for pushing barges on inland waterways and rivers.
Referring to FIGS. 1 and 2 , an exemplary AT/B LNGC is formed by combining a barge portion 1 with a tugboat portion 2 . The barge 1 and tugboat 2 are coupled together with coupling pins 3 such that relative motion is restricted in all degrees of freedom except for pitch. In the AT/B LNGC shown in FIGS. 1 and 2 , the barge 1 includes one or more LNG cargo tanks 4 for storing LNG cargo during transport. As shown in FIG. 2 , the barge 1 has four LNG cargo tanks. However, it should be understood that the number and size of the cargo tanks included in the barge 1 in no way limits the scope of the invention as defined in the appended claims.
FIG. 3 illustrates an exemplary embodiment in which ambient temperature natural gas (i.e., the boil off from the LNG stored in the cargo tanks 4 of the barge 1 ) is transferred from a supply source 17 from the LNG fuel system on the barge 1 through a fuel gas transfer assembly 5 to the supply piping 18 for the natural gas fuel system of the tugboat 2 , where the natural gas will be used as the vessel fuel for the natural gas fueled engines that power the tugboat 2 .
In accordance with an embodiment of the present invention, a fuel gas transfer assembly 5 includes a flexible gas transfer assembly that is suitable for handling ambient temperature natural gas (e.g., LNG boil off) at the required pressure and is suitable for the specific environment in which it is used (e.g., a marine environment). The fuel gas transfer assembly 5 includes a flexible inner transfer hose 6 that is enveloped by a flexible outer jacket 7 . In a preferred embodiment, the inner transfer hose 6 is a stainless steel, corrugated hose (i.e., a Bellows hose). In alternative embodiments, the inner transfer hose 6 may be made of other materials, including regular steel, aluminum, or wire-reinforced rubber, and it should be understood that the material from which the flexible inner transfer hose 6 is made in no way limits the scope of the invention as defined in the appended claims. The inner transfer hose 6 need not even be a hose, but can be any means of transferring the natural gas that is flexible and is compatible with the required LNG pressures and with the surrounding environment.
In accordance with an embodiment of the present invention, a jacket space 30 between the outer jacket 7 and the inner transfer hose 6 is filled with a gas that does not support combustion in the event that natural gas leaks into the jacket space 30 from the inner transfer hose 6 . In a preferred embodiment, the jacket space 30 is filled with an inert gas, preferably nitrogen. However, in alternative embodiments, the jacket space 30 can be filled with other gases that will not support combustion, including but not limited to carbon dioxide, argon, or helium. Here again, the choice of the particular gas that fills the jacket space 30 in no way limits the scope of the invention as defined in the appended claims.
In accordance with an embodiment of the present invention, the inert gas that fills the jacket space 30 is held at a pressure that is higher than the maximum pressure of the natural gas that is within the inner transfer hose 6 . The inert gas is admitted to the jacket space 30 of the fuel gas transfer assembly 5 through a connection 9 located at one end of the fuel gas transfer assembly 5 . A purge connection 8 is provided at the other end of the fuel gas transfer assembly 5 and can be opened to allow the atmosphere within the jacket space 30 to be completely filled with inert gas. Once purging is complete, the purge connection 9 is closed and the pressure within the jacket space 30 is maintained at a pressure that is above the pressure of the natural gas contained within the inner transfer hose 6 . In an exemplary embodiment, the maximum pressure of the natural gas that is within the inner transfer hose 6 is typically 5 bars, and the jacket space 30 is held at a pressure of 6 bars.
In a preferred embodiment, the inert gas, such as nitrogen, is provided from an inert gas source 13 to the fuel gas transfer assembly 5 through a supply line 31 and the connection 9 . A pressure reducing valve 12 is provided in the supply line 31 to deliver the inert gas to the jacket space 30 at the desired pressure. Additionally, the pressure reducing valve 12 can optionally use a feedback loop 32 to monitor the pressure in the inner transfer hose 6 so as to maintain the desired pressure differential between the inner transfer hose 6 and the outer jacket 7 in the jacket space 30 . A flow restrictor 11 is fitted to limit the flow rate of the inert gas to the jacket space 30 to ensure that the pressure in the jacket space 30 drops should a leak develop. A pressure switch 10 is fitted to monitor the pressure of the inert gas in the supply line 31 . If this pressure drops below a predetermined limit, the pressure switch 10 closes, initiating a shutdown signal to terminate the flow of natural gas as well as sounding an alarm to alert operating personnel.
In accordance with an embodiment of the present invention. the fuel gas transfer assembly 5 provides an increased level of safety by ensuring that a leak in the inner transfer hose 6 is captured within the outer jacket 7 , while simultaneously providing for the shutdown of the transfer of the natural gas fuel from the barge to the tugboat and concomitantly sounding an alarm. Should a leak develop in the inner transfer hose 6 , the higher pressure of the inert gas that fills the jacket space 30 between the inner transfer hose 6 and the outer jacket 7 will leak into the inner transfer hose 6 . Consequently, the pressure of the inert gas in the supply line 31 will drop, which in turn will cause the pressure switch 10 to close. In a preferred embodiment, the closing of the pressure switch 10 triggers both the generation of warning alarm signals and a shutdown signal that shuts down the supply of natural gas fuel by closing master gas valves. In an exemplary embodiment, the shutdown signal that is triggered by the closing of the pressure switch 10 ties into the emergency shutdown system of the barge 1 to close the master gas valves of barge 1 . Further, the outer jacket 7 prevents any release of natural gas to the surrounding atmosphere. Similarly, a loss of pressure in the jacket space 30 could occur due to a failure of the outer jacket 7 or a loss of inert gas supply. In any case, a system shutdown will be triggered, ensuring the required level of safety.
In accordance with an embodiment of the present invention, a self-sealing emergency breakaway coupling 14 is fitted to allow the tugboat 2 to exit from the coupling notch of the barge 1 (see FIGS. 1 and 2 ) in an emergency situation. Normally the inner transfer hose 5 would be disconnected from the tugboat 2 by releasing a self-sealing quick connect/disconnect connector 15 from the self-sealing mating connection 16 on the tugboat 2 . In a preferred embodiment, the emergency breakaway coupling 14 is fitted with self-closing valves (not shown) on both halves of the coupling 14 . The coupling 14 is maintained in the normal connected condition by breakaway bolts (not shown) such that when abnormal loads are put on the fuel gas transfer assembly 5 , such as would be experienced when the tugboat 2 pulls away from the barge 1 in an emergency without first releasing the fuel gas transfer assembly 5 , the bolts break at a prescribed load, thereby allowing the halves of the coupling 14 to separate and the internal self-sealing valves of the coupling 14 to close. By closing, the self-sealing valves prevent any release of natural gas to the atmosphere. Other forms of emergency breakaway couplings could be employed without limiting the scope of the present invention.
In accordance with an embodiment of the present invention, partial shields 19 are fitted over the quick connect/disconnect assembly 15 and the mating connection 16 on the tugboat 2 , and over the emergency breakaway coupling 14 on the barge 1 . In a preferred embodiment, each partial shield 19 can be moved to provide access to the couplings underneath (i.e., the quick connect/disconnect connector 15 and the mating connection 16 , and the emergency breakaway coupling 14 so as not to interfere or inhibit the emergency disconnection of the fuel gas transfer assembly 5 . This result can be accomplished by any number of means that are well known to those having ordinary skill in the art, including but not limited to providing the partial shield 19 with a hinge or similar means.
Since the natural gas fuel is at an ambient temperature, it is lighter than air. Therefore, any leakage of the natural gas fuel from the inner transfer hose 6 will rise and will be captured by the partial shield 19 in such a manner that a gas detector 20 located within the partial shield 19 will sense the presence of natural gas before flammable concentrations of the natural gas can accumulate. Upon detection of the natural gas fuel, the gas detector 20 generates a system shutdown signal that is used to cause the flow of the natural gas fuel to be stopped, the fuel system to be put in a safe condition, and an alarm to be sounded. Since the partial shield 19 will concentrate any natural gas fuel at the gas detector 20 , any leakage of natural gas fuel will initiate a system shutdown and an audible alarm.
FIG. 4 shows an alternative to the embodiment shown in FIG. 3 . In the alternative embodiment shown in FIG. 4 , the emergency breakaway coupling 14 is located on the tugboat 2 , adjacent to the mating connection 16 and the quick connect/disconnect connector 15 fitted to the fuel gas transfer assembly 5 . By locating the emergency breakaway coupling 14 on the tugboat 2 , credible leak sources can be concentrated on the tugboat 2 , and the number of partial shields 19 and gas detectors 20 can be reduced to one each versus two each, as illustrated in the embodiment shown in FIG. 3 .
FIGS. 5, 5A, and 5B illustrate an embodiment in accordance with the present invention in which the fuel gas transfer assembly 5 is used in an AT/B LNGC of the type shown in FIGS. 1 and 2 . As shown in FIG. 5 , an AT/B tugboat 2 is coupled to a barge 1 using an AT/B coupler connection, where the reference numeral 3 refers to both the AT/B coupler connection and to the pivot center of the coupling connection. In accordance with an embodiment of the present invention, the fuel gas transfer assembly 5 is flexible and can thus flex within its allowable limits. The fuel gas transfer assembly 5 is supported by a fixed radius saddle 21 to ensure that the minimum allowable bend radius of the fuel gas transfer assembly 5 is not violated.
FIG. 5 specifically illustrates the implementation of the fuel gas transfer assembly 5 that is illustrated in FIG. 4 , wherein the emergency breakaway coupling 14 is located adjacent to the quick connect/disconnect connector 15 and the mating connection 16 on the tugboat 2 . This should not be considered limiting in any way, as the arrangement illustrated in FIG. 3 could alternatively be employed. Although omitted from FIG. 5 for the sake of clarity, it will be understood that the partial shield 19 and the gas detector 20 can be used with the emergency breakaway coupling 14 , the quick connect/disconnect connector 15 , and the mating connection 16 in the manner shown in FIG. 4 . In addition, FIG. 5 (as well as FIGS. 5A and 5B that follow) does not show a termination for the supply source 17 on the barge 1 , since it is to be understood that the supply source 17 terminates wherever the LNG fuel happens to be located on the barge.
FIG. 5A illustrates the embodiment shown in FIG. 5 , with the tugboat 2 pitched at five degrees aft in relation to the level trim of the barge 1 . This represents a typical extreme aft pitch of the tugboat 2 , which can occur as a result of normal at-sea movement of the tugboat 2 relative to the barge 1 in pitch due to the effect of ocean wave conditions, and illustrates the ability of the fuel gas transfer assembly 5 to accommodate the movement between the tugboat 2 and the barge 1 .
FIG. 5B illustrates the embodiment shown in FIG. 5 , with the tugboat 2 pitched at five degrees forward in relation to the level trim of the barge 1 . This represents a typical extreme forward pitch of the tugboat 2 , which can occur as a result of normal at-sea movement of the tugboat 2 relative to the barge 1 in pitch due to the effect of ocean wave conditions, and illustrates the ability of the fuel gas transfer assembly 5 to accommodate the movement between the tugboat 2 and the barge 1 .
FIG. 6 is a composite view of the fuel gas transfer assembly 5 showing the extreme limits of its movement due to the pitching of the tugboat 2 relative to the barge 1 . Reference numeral 3 indicates the center of rotation of the AT/B coupler in pitch (see FIGS. 5, 5A, and 5B ). The fuel gas transfer assembly 5 is supported by the fixed radius saddle 21 , which is fitted on the barge 1 to ensure that the minimum allowable bend radius of the fuel gas transfer assembly 5 is not violated. A similar fixed radius hose saddle 22 is fitted on the tugboat 2 , also to ensure that the minimum allowable bend radius of the fuel gas transfer assembly 5 is not violated. The extreme forward pitch of the tugboat 2 relative to the barge 1 is indicated by position 24 . The extreme aft pitch of the tugboat 2 relative to the barge 1 is indicated by position 25 . The zero pitch of the tugboat 2 relative to the barge 1 is indicated by position 23 .
FIG. 7 illustrates a towboat 26 (i.e., an inland river push-mode tugboat) that pushes an LNG fuel barge 27 as part of a flotilla of cargo barges of various types, in accordance with another embodiment of the present invention. As shown in FIG. 7 , natural gas fuel is transferred from the LNG fuel barge 27 to the towboat 26 in the manner described hereinabove, wherein the fuel gas transfer assembly 5 , the natural gas supply line 17 from the natural gas supply on the barge 27 , the natural gas supply line 18 to the natural gas-fueled engines on the towboat 26 , the emergency breakaway connector 14 , the quick connect/disconnect connector 15 , and the mating connection 16 are fitted on the towboat 26 and the barge 27 in the manner illustrated and described hereinabove.
FIG. 8 illustrates another embodiment in accordance with the present invention, in which a railroad locomotive is powered by ambient temperature natural gas fuel (e.g., LNG boil off) that is provided from a tender car 29 . As shown in FIG. 8 , natural gas fuel is transferred from the tender car 29 to the locomotive 28 in the manner described hereinabove, wherein the fuel gas transfer assembly 5 , the natural gas supply line 17 from the natural gas supply on the tender car 29 , the natural gas supply line 18 to the natural gas-fueled engines on the locomotive 28 , the emergency breakaway connector 14 , the quick connect/disconnect connector 15 , and the mating connection 16 are fitted on the locomotive 28 and the tender car 29 in the manner illustrated and described hereinabove.
While this invention has been described in conjunction with exemplary embodiments outlined above and illustrated in the drawings, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting, and the spirit and scope of the present invention is to be construed broadly and limited only by the appended claims, and not by the foregoing specification. Without limiting the generality of the foregoing, those skilled in the art will appreciate that the embodiments in accordance with the present invention are not limited to the transfer of LNG and include and encompass the transfer of other cryogenic liquid gases.
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Natural gas is produced when LNG that is contained in an insulated LNG cargo tank(s) of a non-self-propelled LNG carrier (i.e., a barge) evaporates as a result of heat leakage through the walls of the insulated cargo tank(s). The natural gas is transferred from the barge to a tugboat or a towboat that is equipped with natural gas burning engines through a flexible gas transfer assembly so that the tugboat is powered by the natural gas fuel. The pressure in the cargo tank(s) on the barge is, therefore, effectively managed to prevent or substantially reduce the buildup of pressure within the LNG cargo tank(s). The LNG can then be contained within the LNG cargo tank(s) for an appropriate period of time and can be delivered at an appropriate and acceptable equilibrium pressure and temperature.
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This is a continuation, of application Ser. No. 851,227 filed Nov. 14, 1977.
BACKGROUND OF THE INVENTION
Sprayers for liquids, particularly, those of the hand-operated trigger type, ordinarily include a check valve in a chamber located just inside the sprayer outlet which serves to block off the inlet passage to the chamber from the interior of the sprayer until the liquid becomes pressurized and to block the passage of liquid from the chamber except to allow it to pass through certain swirl or other passages to the outlet. For instance, U.S. Pat. No. 3,685,739 to Vanier shows a shuttle valve which is free to move in a sprayer outlet chamber wherein upon operation of the sprayer a partial vacuum downstream of the chamber causes it to block the entrance of air through the outlet orifice into the pumping means of the sprayer by closing the liquid supply passage after which the shuttle moves in the opposite direction as the pressure of the fluid in the supply passage builds up and blocks the outlet except for the swirl passages.
Another U.S. Pat. No. 3,061,202 to Tyler shows a check valve which achieves the same general purpose as that of Vanier but is spring-loaded so that it remains on its seat to close the liquid supply passage at all times except when the sprayer is operated to create a sufficient pressure in the supply passage to overcome the spring and thus force the valve to open. Flow of the fluid to be sprayed then occurs, in each instance, to a swirl chamber from which it is sprayed through an outlet orifice. The inlet passage 35 of Tyler is closed by a conical poppet 29 in his showing but flat poppets have been used for this purpose as well. The present invention is an improvement in this art and is distinct from it in that the swirl chamber closure plate, the spring and the poppet are all made of one-piece as a unitary, molded construction thus eliminating the need for three separate parts as shown by Tyler and yet still achieving the same desirable flow and shut-off characteristics. Elimination of the plurality of parts means less assembly time and thus less cost of manufacture, improved simplicity, one-piece reliability and the elimination of compatibility of material problems and problems associated with metal parts such as corrosion for instance.
Another U.S. Pat. No. 3,620,421 to MacGuire-Cooper shows a valve requiring lateral movement of the valve to tilt it on its seat to open the outlet to the flow of a product from its container below the valve. A resilient annular portion is provided which acts to restore the valve to its closed position and this annular portion is molded integrally with the valve portion. In the present invention, on the other hand, the valve is linear in its action and includes an integrally molded sinuous spring which compresses only upon the application of proper operating pressure supplied by the pump action of the sprayer, and, the sinuous spring is carefully designed and molded to operate only when the pressure is sufficient to produce a spray.
OBJECTS OF THE INVENTION
It is, therefore, an object of the present invention to provide a check valve for the exit chamber of a fluid sprayer which includes a sinuous spring and the valve poppet all in one molded piece.
It is also an object of the present invention to provide a check valve as in the foregoing paragraph which includes not only the sinuous spring and valve poppet but also a spin element all in one unitary molded piece.
It is also an object of the present invention to provide a check valve as described in the preceding paragraphs but including a spring in the shape of a letter S.
It is also an object of the present invention to provide a molded one-piece valve, spring and spin element assembly having the reliability of a unitary assembly, ease of manufacture and therefore less costly, resistant to corrosion and having no metal parts.
It is also an object of the present invention to provide a mount for the spin element which prevents possible mold sinks at the center of the spin element.
Other objects and advantages of the present invention will become apparent from the detailed description and claims which follow.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-section in front elevation of that portion of the sprayer which includes the invention. The unitary assembly including the spring and a portion of the sprayer itself is shown solid and not in cross-section for purposes of clarity. The sprayer is in the normal or at rest condition.
FIG. 2 is a view similar to that of FIG. 1 except that the sprayer is in the pressurized or spraying condition and swirl passages are shown in its nose piece.
FIG. 3 is a view of the outlet wall side face of spin element 17c taken in the direction indicated by the arrows 3--3 in FIG. 1 and showing the swirl passages in its face.
FIG. 4 is a view of the inner side of the outlet wall taken in the direction indicated by the arrows 4--4 in FIG. 2 and showing its swirl passages.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 of the drawings, a trigger operated pump type sprayer is shown having a body 10 with a cylindrical nose cavity or bore 11 into which a closely fitted nose piece 12 is inserted by a force fit to effect a fluid tight seal therebetween. An outlet or orifice 13 is provided in the front or outer wall of nose piece 12 and the interior of nose piece 12 is hollow as shown to provide a chamber 14. To the right of chamber 14 in FIG. 1, is a passage 15 in body 10 which opens into chamber 14 and defines an annular shoulder 16 in the manner shown. Inside chamber 14, and inserted before nose piece 12 is forced in place, is a unitary molding including a spring, a valve poppet and a swirl chamber cover or spin element all in a one-piece integral molded assembly 17 which, when it is molded, is purposely made longer than chamber 14 so that the spring 17a will be slightly compressed between the end walls of chamber 14 when nose piece 12 is put in place in body 10.
The unitary molding 17 includes, as previously mentioned, a spring 17a a transversely deployed poppet disc or valve piece 17b and a transversely deployed outlet blocking spin element or disc 17c all attached together with the spring 17a between the other two portions and connected to each of them by molded posts 17d and 17e. Disc 17c is preferably attached to post 17d by an arch or arcuate bridge 17f which is open at its center and spans disc 17c connecting with it near the disc's periphery and with post 17d at the peak of its arch. With this construction, the face of disc 17c opposite the outlet is kept flat without any possible mold "sink" as its center to cause distortion sufficient to prevent it from seating properly on the outlet wall of chamber 14.
Again with reference to FIG. 1, the inner outlet wall of chamber 14 is plain and flat but disc 17c has one or more channel-like passages 18, 19 formed in its face which lead from its outer extremities inwardly toward outlet 13 and communicate with it but are directed tangentially thereto. These are shown more clearly in FIG. 3. Disc 17c rests firmly against the face of the outlet wall which acts as a wall to define passages 18, 19 by closing their otherwise open channels to make a four-sided passage or conduit. Disc 17c, however, is of smaller diameter than that of the outlet wall so that the outer or end portions of passages 18 remain uncovered and open to chamber 14 but three or more small discs centering integrally molded bosses 17g can be used on disc 17c spaced equally about its periphery to keep it away from the wall and thus to preclude any possible partial blocking of the fluid by the resting of the disc 17c against the inner side wall of nose piece 12 due to non-centering. The overall diameter of the disc 17c and the bosses 17g is less than the internal diameter of nose piece 12 to allow clearance for free movement of disc 17c longitudinally of nose piece 12.
At the opposite end of chamber 14 is a flat, round disc or poppet 17b which in the normal and unpressurized condition of the sprayer is urged against annular shoulder 16 by the biasing effect of the slight compression of spring 17a to block off passage 15 to prevent the flow of liquid past that location.
In another version of the nose piece 12, swirl passages 20, 21 are provided in the nose piece 12 itself rather than in the spin element or disc 17c as shown in the view of the inner face of the outlet wall in FIG. 4. These passages are again directed tangentially to outlet 13.
OPERATION OF THE INVENTION
With reference to FIG. 1, the sprayer is operated in the usual manner by manipulation of the trigger 22 back and forth to pump liquid up from a container (not shown) into passage 15 where it exerts pressure on valve poppet 17b. When this pressure becomes sufficient to further compress spring 17a, poppet 17b is forced to the left in FIG. 2 leaving annular shoulder 16 and thus permitting pressurized fluid to pass from passage 15 into chamber 14 which it fills. When the chamber 14 is completely filled, the fluid enters swirl passages 20, 21 and enters outlet orifice 13 with a rotary spin or swirl motion induced by the force couple caused by the tangential approach of the fluid through passages 20, 21 to the outlet. The fluid then is forcefully ejected from outlet 13 in a spray due to the pressure upon it and the swirl effect.
When the fluid which was originally pumped into the sprayer from its container becomes exhausted, the trigger is allowed to return to its normal at rest position whereupon a slight vacuum occurs in passage 15 and normal atmospheric pressure inside chamber 14 returns poppet 17b to its seat on shoulder 16. The cycle can be repeated again and again to cause the sprayer to spray as desired until the contents of the container is exhausted.
With the configuration shown in FIGS. 1 and 3, the operation is identical with the fluid entering the passages 18, 19 in disc or spin element 17c instead of in the nose piece 12 itself.
It is to be noted that the disc 17b remains seated on the inside of the outlet wall at all times in both configurations and does not move.
The configuration of the spring 17a is preferably that of an S as shown in the drawing but other sinuous spring shapes can be used if desired such as a simple loop, split S, double S, helix or other sinuous shape providing that it fits within the chamber 14 without binding or interference with its walls, particularly when compressed. The spring rate or force required to compress the spring can be varied during the molding of the assembly by altering the molding dies to provide various dimensions for the spring and also by the use of various materials with different elastic properties or tensile strengths. It can, for instance, be made weaker by making the spring narrows or thinner or stronger by increasing its width and thickness.
It is preferred that the assembly be molded of a plastic material such as polypropylene or polyethylene but other plastics can be used provided that they have the qualities required to provide compatibility with the fluids being sprayed, dimensional stability sufficient to prevent undue changes in the spring characteristics, to prevent binding in chamber 14 or to prevent changes in flatness, the resiliency needed to provide the spring effect, and, good moldability.
While there have been shown and described and pointed out the fundamental novel features of the invention as applied to a preferred embodiment, it will be understood that various omissions and substitutions and changes in the form and details of the device illustrated and in its operation may be made by those skilled in the art, without departing from the spirit of the invention. It is the intention, therefore to be limited only as indicated by the scope of the following claims.
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A spring-loaded double-ended check valve assembly is provided for use in the outlet chamber of a dispenser for spraying liquids. The entire assembly, including both ends and the spring, is made in one-piece and is easily moldable from plastic material thus effecting ease of manufacture and assembly into the sprayer, reduced labor and material costs and affording the reliability of a unitary member.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to and the benefit of the filing of U.S. Provisional Patent Application Ser. No. 60/985,179, entitled “Software for Securely Consolidating, Managing, Enriching and Distributing Personal Data and Content”, filed on Nov. 2, 2007, and the specification and claims thereof are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable.
COPYRIGHTED MATERIAL
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention (Technical Field)
The present invention relates to methods, software, and apparatuses for online identity management and identity verification.
2. Description of Related Art
With the plethora of user registrations that the typical World Wide Web (“Web”) user creates, it becomes nearly unmanageable to maintain consistent information between them, and to provide concomitant appropriate levels of information to the various Web sites for which registrations exist. No satisfactory solution for this problem is currently available that also provides ongoing identity validation and management and/or that provides users with security independent of the host system. The present invention solves this and other problems with the current chaotic state of affairs.
BRIEF SUMMARY OF THE INVENTION
The present invention is of a user identity verification apparatus and method comprising, via one or more processors: collecting in a computer database consolidated user data comprising information about a method user from a plurality of sources comprising credit bureau information, information from data vendors, and public information; generating a profile of the method user comprising a plurality of subsets of the consolidated user data corresponding to a plurality of access levels; receiving a validation request from a third party source at an unknown user's request; assigning an access level to the validation request; requesting information from the unknown user; matching returned information from the unknown user to that in the subset of the consolidated user data corresponding to the assigned access level; and verifying to the third party source that the unknown user is the method user. In the preferred embodiment, the requested information comprises information from a credit bureau. Altering the profile of the method user is done as information from the plurality of sources changes over time, preferably the prompting the method user to enter matching changed information in order to maintain a validated status. The invention allows the method user to alter the profile, followed by verifying with the plurality of sources that the alteration to the profile is accurate. The method can be used by an unknown user seeking authorization by the third party via a two-factor authentication process. The invention can mark a profile as that of a parent or a child, wherein the profiles can be linked such that parents have control over the profiles of the children. A contact manager can be established for the method user containing information on other users and an indication of whether such other users have been verified by the method.
Further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings:
FIG. 1 is a schematic diagram of the Profile Manager and the Identity Engine of the invention;
FIG. 2 is a schematic diagram of the creation of a validated profile according to the invention;
FIG. 3 is a schematic diagram of the monitoring and updating of profiles according to the invention;
FIG. 4 is a schematic diagram of the monitoring of profile validation according to the invention;
FIG. 5 is a schematic diagram of the use of the invention to provide two-factor authentication;
FIG. 6 is a schematic diagram of the verification of a user as a parent according to the invention;
FIG. 7 is a schematic diagram of the verification of a user as a minor/child according to the invention; and
FIG. 8 is a schematic diagram of the Contact Manager of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is of a method, software, and apparatus for managing online identify information. The invention comprises one or more of the following components:
1. Identity Verification Engine (IVE). A back-end system that provides identity verification for internet sites. System allows sites to segregate their users into multiple validation levels, like government security clearance levels. Each level preferably requires more information from credit and other records. Example levels are: light, basic, secure, child-safe, and credit-worthy. The invention preferably also provides iconography to establish cross-site validation branding.
2. Personal Identity Manager (PIM). A website that allows consumers to generate their own validated internet profiles, preferably using the same security levels and iconography as the Identity Verification Engine. Users can post these icons on sites who have not licensed the IVE through pre-developed widgets, HTML embeds, and links.
3a. Web-based 2-factor authentication. A website that verifies individual identity through rigorous out-of-wallet questions, and then pares that verification with a corporation's username/password verification. The result is 2-factor (something you know plus something you are) verification, which can be used for remote intranet login, private spaces in public sites and virtual networks.
3b. Parent 2.0. This component links identity verification to social networks for minors. The Personal Identity Manager expands to include identities for children, and maps of their social networks. Parents can restrict children to only making “friends” with children who have verified parents. The invention then preferably provides contact information for other parents. The invention then alerts parents of all social ties that their children establish. The invention can also provide call center escalation for concerned parents (regarding, e.g., internet bullying, suspicious profiles, inappropriate content, etc.).
4. Internet Identity Manager. This component provides a single interface for managing all social network identities, including global friends list, aggregate media bins, cross-site blog publishing, and drag-and-drop network populating. This preferably requires a critical mass of social networks to adopt an open standard and allow for remote login and third party network manipulation. An individual could select various aspects of his identity (address, contact info, credit worthiness) to publish on different networks and sites. The invention can extend beyond social networks to serve as an identity “wallet” for partner sites.
5. Next Generation Credit Score. This component provides for merging of interpersonal network data with credit data (which comes with verification). Whereas credit scores are history-based, and re-active, network association data allows prediction of loan risk, even in the absence of transactional history. Social network analysis also allows for the creation of new “archetypes” which will add dimensions to credit risk, individual's popularity, and like analyses.
The capabilities of the invention include the abilities to:
1. Provide users who are virtually connected to other users' confidence that those other users are who they purport to be.
2. Monitor user profile changes within a system to flag potential identity fraud.
3. Monitor external changes to private data to flag internal-external discrepancies.
4. Give networked communities the ability to define identity in terms of the specific context for which the communities exist (dating, business, trade, employment) and monitor those identities in that context.
5. Give users the ability to verify their own identities in virtual environments where no uniform method of verification exists.
6. Allow minors to take advantage of virtual communities safely.
7. Give parents tools to protect their children online from bullies, predators and sexual offenders.
8. Expand the networking tools available to businesses by providing two-factor authentication for public, un-secure environments.
9. Give user users the ability to manage all their authenticated contacts in one interface, regardless of the origin of those contacts.
10. Predict future changes of user identity components by analyzing the user's larger network over time for relevant patterns and indicators.
11. Let users disclose varying degrees of their private information (social, geographic, financial) depending their priorities.
12. Decrease identity fraud and increase user confidence by reducing the fear of identity theft and online security.
13. Give users a level of identity security independent of the identity protection measures of a particular system that requires private information.
14. Increase participation in networked systems by certifying the identities of all participants in the system.
15. Implement an “immunization” model of virtual communities, where every user is certified as authentic and valid, rather than the current “sterilization” model of virtual communities, where the burden is on the system to be secure and imposter-free.
For purposes of the specification and claims, the following terms are defined:
Child—a minor user on a system who has verified parents on that same system.
Contact Manager—The contact manager of the invention gives individual users visibility and screening control over all their contacts via the profile manager and the identity engine. The contact manager also provides communication tools, messaging, blocking and visibility controls, extending the functionality of the systems for which the profiles exist. The contact manager is further illustrated in FIG. 8 .
Data Sources—Vendors, databases, public records, and other repositories of user information.
Identity—the compellation of data elements that serves to represent a user totally and uniquely, in a particular context. Those data elements include, but are not limited to, physical address, age, social security number, hospital records, employment records, credit scores, financial history, rental history, educational history and criminal records.
Identity Engine—The identity engine of the invention uses information from data sources, as well as information collected within the invention, combined with its own analysis, to create data identities for all users, and to monitor changes to those data identities. The identity engine is further illustrated in FIG. 1 .
Identity Fraud—when a user presents the data from another user's “identity” to either specifically pose as that other user, or obfuscate his or her own identity.
Minor—a user under 18. Minors cannot have profiles verified by the invention unless they have a parent that is also verified on the system.
Parent—the legal guardian of a minor in question.
Profile—the subset of identity data presented in a virtual context as a proxy for identity. Most virtual profiles require some identity information (name, address, birthday, etc.) and others offer the option of disclosing more (credit ranking, income levels, employment history, etc.) In addition, virtual profiles are not always required to be completely or partially accurate. The extent to which a profile should be monitored for fraud depends on the authenticity requirements in that system.
Profile Manager—The profile manager of the invention tracks all the profiles a user creates, as well as the specific pieces of private information comprising those profiles. The profile manager also creates a master profile that links all the user profiles together. The master profile is used to connect with the identity engine, therefore resolving the many-to-one relationship of profiles to user. The profile manager is further illustrated in FIG. 1 .
System—anything that requires a user to uniquely identify him-her-or-itself with some distinguishing piece of information. It could be a phone system (cell phone number,) a website (username-password), an intranet, gaming application, etc. The system is a virtual context for users to connect and communicate with each other, or to interact with some larger central entity (a bank, a corporation, etc.)
Two-factor Authentication—a system wherein two different factors are used in conjunction to authenticate a user. An authentication factor is a piece of information or process used to authenticate or verify a person's identity or other entity requesting access under security constraints. Human authentication factors are generally classified into three cases:
1. Something the user has (e.g., ID card, security token, software token, phone, or cell phone);
2. Something the user knows (e.g., a password, pass phrase, or personal identification number (PIN)); and
3. Something the user is or does (e.g., fingerprint or retinal pattern, DNA sequence (there are assorted definitions of what is sufficient), signature or voice recognition, unique bio-electric signals, or another biometric identifier).
The invention creates a new type of factor #3—something the user is—by compiling a unique set of identity data and using that data to facilitate user profile validation.
User—the physical user or entity. When users interact with systems, they do so by their profiles. But these users or entities also take action outside the systems—i.e. in the physical world.
User-System Interface—the method the user is required to use for creating profiles on, and interacting with, a system. In addition to working with other systems, the invention will include its own user-system interfaces, for users to manage and validate their identities on non-integrated systems.
Verified/Validated—these terms are used interchangeably. They mean that the invention considers the user's profile as accurately representing the individual, in the context of the system for which the profile was created. The invention determines the validity of a profile independent of the system, which allows the invention to maintain credibility and independence from the systems with which it communications.
FIG. 1 illustrates a user establishing profiles on a variety of systems that require registration: a website, a mobile device, a software system and a networked application. In each case, the user is asked to create some kind of unique identifier (login, password, etc.) and to provide some amount of private information as part of registration. The four different shaded icon fractions represent different sets of private information, since no profile requires all the information that comprises a user's identity.
Each of these systems is connected with the profile manager (part of the invention.) The profile manager tracks each unique profile on each system, and the specific private data elements associated with those profiles. The profile manager also creates a master profile that links all of the system profiles together (the whole shaded icon in the profile manager box.) Because a user can have multiple profiles set up on multiple systems, the consolidated profile serves as a one-to-many link between the actual user and his/her/its multiple profiles.
The profile manager communicates with the identity engine (part of the invention.) The identity engine creates detailed records of all the users who have profiles authenticated by the invention. The data it compiles is a product of credit bureau records, public records, data vendors and its own analysis. There is only one record for each user in the identity engine. The consolidated profile in the profile manager serves as the link between the master record in the identity engine and the multiple profiles stored in the profile manager.
FIG. 2 demonstrates how a user creates a validated profile on a system. The user visits the user-system interface to create the profile. The user-system interface asks the user to input some unique private information, a subset of the total set of private information that comprises the user's virtual identity. In addition to whatever information the system requires for its own purposes from the user, the system-user interface must also request enough information for the invention to certify that the user is verified as authentic. The owners of the system and the owners of the invention will determine the criteria that satisfy authenticity.
The user-system interface then communicates the user information to the profile manager, which creates a new profile record, and then makes an identity query to the identity engine, using the profile data submitted by the system-user interface.
The identity engine determines whether or not it has a record for the user in question. The identity engine would have an existing record if the user had submitted for a verified profile through some other system, or through the same system using a different profile. If no pre-existing record exists, the identity engine will access various data sources to determine if the user is who he/she/it presents itself to be. If a pre-existing record does exist, the identity engine will determine whether or not, in this particular instance, the user has submitted sufficient/correct information to verify the new profile the user has just created. It is possible for a user to create a profile that is unverifiable, even if that user has previously created profiles that are verifiable.
If the identity engine verifies that the user, in this particular case, has submitted valid information, it sends confirmation to the profile manager. The profile manager in turn communicates that confirmation to the system user interface. That confirmation can be an icon, a symbol, text, a hyper-link, or a Boolean flag. Some systems may allow unverified users to have profiles. Systems may also allow degrees of verification, which the profile manager will be able to support. Other systems may require verification, and reject the profile creation out-right if the user is not verified. Regardless of what the system permits, the invention will maintain its standards of verification independent of the system.
If the identity engine cannot verify the user based on the profile information submitted, there are two options. The identity engine can request more user information, or it can reject the verification request.
If the identity engine determines that more user information may resolve the discrepancy, it will provide the user-system interface (either directly, or through the profile manager) a set of challenge questions or data requests for the user. Based on those answers, the identity engine will repeat the process of reconciling profile data against user identity data to determine if the profile can be verified. The invention will determine the number of times the “supplemental data request” cycle will be repeated.
If the identity engine rejects the verification request, the profile manager withholds profile validation. The system then has the option of permitting or refusing profile application, but the profile will not be verified, and there will be a clear distinction on that system between the unverified profile and other verified profiles.
FIG. 3 explains how the invention monitors a user's identity and updates the profile status on a particular system, when the changes to a user's identity data occur outside of the system. A user's identity data can change due to a wide range of factors. The user can change addresses, change names, take action which generates public records (criminal records, property ownership, marital status, etc.). It can also take action which affects records compiled by private entities (credit bureaus, profiling companies, insurance records, etc.).
The identity engine monitors these data sources for the user identity records it maintains. Some data sources offer services, such as credit monitoring, which automatically update subscribers of any record changes. For data sources where no such service is automated, regular polling and random inquiries will keep the identity engine up-to-date. In addition, the identity engine will have algorithms which prompt record inquiries (such as monitoring address/employment discrepancies, multiple marriage records, etc.).
When a user's identity data changes, the identity engine alerts the profile manager of the changes. The profile manager determines whether or not those changes impact any of the user's profiles. Some identity changes will have no affect on a user's or profiles. Change of marital status, for example, may have no impact on a profile created in an auction system. But that same change might affect the user's profile on a dating website. For all the profiles affected by the change, the profile manager has the relevant system alert the users. The users are prompted to update their profile information. If the users correctly update their profiles, the profile manager preserves the verified status. If the user incorrectly updates the system, or does not update the system, or the system elects not to notify the individual for changes, the profile manager removes the ‘validated’ status.
It is possible for the invention to validate a profile, and for the system that created the profile to invalidate it. In the above-mentioned example, the user's marital status changed. If that change was from ‘single’ to ‘married’ and the dating website did not allow married participants, the website could reject the user. In such a case the user's profile would be validated, in the sense that it was accurate, but be rejected by the system, which did not allow married individuals.
Note that FIG. 3 assumes the existence of an initially valid profile, as described in FIG. 2 .
FIG. 4 explains how the invention monitors profile validation when the user updates his/her/its profile within the system. When a user changes a profile, the user-system interface notifies the profile manager if that change affects profile validation. The profile manager takes three steps. It changes the user's profile validation status to “pending.” It notifies the user that the profile in question is being reviewed for validation. And it maps that profile to the master profile it maintains, which links to the identity engine.
The identity engine checks its records and queries its data sources and determines whether or not the new information provided in the system matches with the user's identity data. If the new information matches the identity data, the profile manager restores the profile's “validated” status and notifies the user. If the new profile information does not match the identity data, the profile is no longer verified. The profile manager removes the verified status, and notifies the user.
There will, of course, be the possibility for appeal, and manual intervention. But the end result of that appeal or intervention process must result in a synchronizing of the information presented in the profile and the data stored in the identity engine.
Note: FIG. 4 assumes the existence of an initially valid profile, as described in FIG. 2 .
FIG. 5 illustrates how the invention is used to facilitate two-factor authentication. The invention will satisfy the “something you are” criteria with a verified user profile, since the validation of that profile depends on records and systems not under the user's control. In this case, the user logs on to the system using a verified. The profile manager maps that profile to its master profile, which in turn maps to the user's identity data.
The identity engine retrieves the user identity data, the scope of which exceeds any personal information stored by the system, in the profile or otherwise. Based on that information, the profile manager (through the user-system interface) offers challenge questions, the answers to which only a person with access to the entire user identity data profile would know. These questions are not limited, in scope, to the context of the system. For example, a person logging on to a corporate website could receive challenge questions about his student loans or his previous addresses.
If the user correctly answers enough of the challenge questions (the threshold being determined by the system and the owners of the invention) the profile manager authenticates that the user is “who” he/she/it is, and grants access to the system. If the user fails the challenge questions, the invention will not verify that the user “is” who the user is, and will fail the user's authentication process.
Note: FIG. 5 assumes the existence of an initially valid profile, as described in FIG. 2 . It also assumes the ongoing monitoring of that profile, as described in FIGS. 3 and 4 .
FIG. 6 illustrates how the invention verifies a user as a parent. In general, the invention does not constrain users to be individuals, but in this use case, the user must be an individual. The user accesses the system, and either in the process of creating a profile, or post-profile creation, identifies him/herself as a parent. A user without a verified profile cannot be a parent, and if the user is creating a new profile, the verification process outlined in diagram #1 must be done prior, or in conjunction with, verifying as a parent.
Assuming that the user has a verified profile on the system, the profile manager maps that profile to the user's master profile, which in turn maps to the user's identity data.
The identity engine screens the parent for appropriateness. The exact criteria used to determine appropriateness is proprietary, but will include age screening, criminal record checks, sex offender checks, logged user complaints, and other data. If the identity engine determines that it cannot verify the individual as a parent, it will deny the user ‘parent’ status. This will not necessarily affect the profile's general ‘verified’ status.
If the user passes the screening, the profile manager will require the user to provide additional information that may or may not be contained in the user's system profile. That information will include, but is not limited to, physical address information, electronic contact information, email reply confirmation, etc. If the user provides the requested information, the invention will grant the user's profile ‘parent’ status. If not, that status will be withheld.
Note: FIG. 6 assumes the existence of an initially valid profile, as described in FIG. 2 . It also assumes the ongoing monitoring of that profile, as described in FIGS. 3 and 4 .
FIG. 7 illustrates how the invention verifies a user as a child. A user must create a new child profile in the system-user interface. Existing verified profiles cannot be changed to ‘child’ profiles since, to pass the invention's validation process without a parent (i.e. without being a child) the user cannot be a minor.
The profile manager maps the child profile to a master profile (since a child user may have child profiles on other systems that allow parent-child verification by the invention.) The identity engine then confirms that the applicant is a minor by accessing the data sources that can confirm minor status.
If the applicant is a minor, the profile manager has the system-user interface procure the profile of the parent. If the user fails to provide a parent with a verified profile, the application for ‘child’ status is rejected. If the user provides a parent verified profile, the profile manager screens the approved profile to determine if the submitted parent is, in fact, the parent of the child. This screening process will include, but is not limited to, address checking, call-back confirmations, email confirmation, etc. The screening process may involve requesting additional information, listing of references, or any other steps the invention requires vouching for the parent-child relationship. This screening step is necessary because it is possible for an adult to pass the parent screening process, and for a minor to pass the child screening test, and for that parent not to be the actual parent of the minor in question. The parents of a child's best friend (who is also a minor) cannot, for example, be listed as parents of the applicant child, even if those parents have children who are already on the system.
Note: FIG. 7 assumes the existence of a parent profile, as described in FIG. 6 . FIG. 7 also assumes the ongoing monitoring of itself, as described in FIGS. 3 and 4 , as well as the ongoing monitoring of the parent profile.
FIG. 8 illustrates how the contact manager (part of the invention) allows a verified user to verify his/her/its contacts on all systems for which the user has profiles. The invention will, in effect, extend the verification benefits that systems enjoy to individual users of those systems.
The user in this case has profiles on several systems. These profiles have been verified by the invention. The invention can also manage contacts for systems where the user does not have a verified profile, but the user may not have full access to the invention's functionality in that case. For each system in question, the invention will display all the user's contacts, and indicate whether or not those profiles have been verified by the invention. The user can regulate visibility, information access, contact permissions, and a range of other controls, based on the validity of the user's contacts.
The invention may be used to explore and establish new contacts, communicate with contacts, and in general extend the communication functionality of the systems for which the profiles exist.
The invention also offers notification services, automatic screening, warning and blocking based on the changing validity of the user's contacts.
Note: FIG. 8 assumes the existence of an initially valid profile, as described in FIG. 2 . It also assumes the ongoing monitoring of that profile, as described in FIGS. 3 and 4 . It further assumes that any contact represented as verified has been subject to the same creation and ongoing monitoring criteria.
In one embodiment, the present invention utilizes personal computer-based client/server architecture comprising one or more processors (such as a microprocessor or central processing unit (CPU)). As Web interface technology matures, other embodiments of the present invention, using very similar if not identical architecture, might well be implemented over the Internet or other successor or predecessor wide-area networks. Under such embodiments, the “server” might be any set of computers on the Internet that look like a single data source to the client. The “client” might be any computer, portable digital assistant, cellular telephone, and like devices on the Internet running one of several commercially available browsers. Any programming language(s) and database systems can be employed, including Visual Basic, C++, Java, SQL, and the like.
Note that in the specification and claims, “about” or “approximately” means within twenty percent (20%) of the numerical amount cited.
Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference.
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A user identity verification apparatus and method comprising, via one or more processors, collecting in a computer database consolidated user data comprising information about a method user from a plurality of sources comprising credit bureau information, information from data vendors, and public information, generating a profile of the method user comprising a plurality of subsets of the consolidated user data corresponding to a plurality of access levels, receiving a validation request from a third party source at an unknown user's request; assigning an access level to the validation request; requesting information from the unknown user, matching returned information from the unknown user to that in the subset of the consolidated user data corresponding to the assigned access level, and verifying to the third party source that the unknown user is the method user.
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[0001] This application is a Divisional of U.S. patent application Ser. No. 13/236,587, filed Sep. 19, 2011, which is hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to modifying small structures using localized electrochemistry and is particularly useful in the field of nanotechnology.
BACKGROUND OF THE INVENTION
[0003] Micrometer and nanometer scale structures are used in many fields including biological sciences, microelectromechanical systems (MEMS) and semiconductor manufacturing. For example, semiconductor devices such as microprocessors can be made up of millions of transistors, each interconnected by thin metallic lines branching on several levels and electrically isolated from each other by layers of insulating materials. Biological sensors may include microscopic regions of biological material that detect an analyte, transducers and electronics that provide an interpretable detectable signal.
[0004] When a new nanoscopic device is first produced in a fabrication facility, the design typically does not operate exactly as expected. It is then necessary for the engineers who designed the device to review their design and “rewire” it to achieve the desired functionality. Due to the complexity of lithography processes typically used to fabricate microstructures, it typically takes weeks or months to have the re-designed device produced. Further, the changes implemented frequently do not solve the problem, or the changes expose another flaw in the design requiring additional design changes. The process of testing, re-designing and re-fabrication can significantly lengthen the time to market new semiconductor devices. Device editing—the process of modifying a device during its development without having to remanufacture the whole circuit—provides tremendous economic benefits by reducing both processing costs and development cycle times.
[0005] Charged particle beam systems, such as focused ion beam systems and electron beam systems, are used to create and alter microscopic structures because the charged particles can be focused to a spot smaller than one tenth of a micron. Focused ion beams can micro-machine material by sputtering that is, physically knocking atoms or molecules from the target surface or chemically assisted ion beam etching. Electron beams can be used in chemically-assisted electron beam etching.
[0006] Ion beams, electron beams, and laser beams can also be used to directly deposit material by a process known as beam-induced deposition or direct-write deposition. Direct write deposition allows a device designer to test variations of the device without undertaking the lengthy process of modifying photolithography masks and fabricating a new circuit from scratch. Direct write deposition can be achieved by using electron beam, ion beam, or laser beam stimulated chemical vapor deposition, in which a precursor species dissociates due to the effects of the beam. Part of the dissociated molecules is deposited onto the substrate, and part of the dissociated molecule forms volatile by-products, which eventually release from the substrate surface. The precursor can be a vapor that contains a metal species to be deposited. The metal is deposited only in the area impacted by the beam, so the shape of the deposited metal can be precisely controlled. An ion beam assisted deposition process is described, for example, in U.S. Pat. No. 4,876,112 to Kaito et al. for a “Process for Forming Metallic Patterned Film” and U.S. Pat. No. 5,104,684 to Tao et al. for “Ion Beam Induced Deposition of Metals.”
[0007] It is often difficult to obtain high purity materials using direct write deposition, primarily due to the incorporation into the deposit of other components of the precursor molecules or the elements from the incident ion beam, such as gallium ions. This lack of control of composition, material purity, or internal structure often leads to undesirable properties in the deposited material. Tungsten and platinum deposited by focused ion beam (FIB)-induced deposition typically have resistivities greater than about 150 micro ohm centimeters (μΩ-cm). Recently-introduced FIB copper depositions have resistivities of 30-50 μΩ-cm. This is significantly higher than the resistivity of pure copper, which is less than 5 μΩ-cm. As conductor sizes continue to shrink and processor speeds increase, it will be necessary to reduce the resistivity of conductors deposited during the device edit process, so that the smaller conductors can carry the required current. Similarly, the resistivity of material used to fill vias, metal filled holes that connect conductors in different layers, will need to decrease because the diameter of vias will decrease in the future so there is less conductive material in the hole to carry current. Low resistivity of the fill material and elimination of voids thus becomes even more important. Also, as via dimensions decrease, it becomes more difficult to cleanly sever a line at the bottom of the via without redepositing conductive material on the sidewalls of the via, which can short circuit other layers.
[0008] Furthermore, the materials that can be deposited by charged particle beam-induced deposition are limited by the availability of vapor phase precursors with requisite properties, that is, high residency time (stickiness) on the surface, lack of spontaneous decomposition, and decomposition in the presence of the beam to deposit the desired material and form a volatile byproduct. When suitable deposition precursors do exist for a particular material, the deposition rates are often limited by gas depletion effects and other factors.
[0009] Processes for applying metal globally to a circuit are known. For example, copper electroplating has been used by IC manufactures to make on-chip interconnection in the Damascene process, originally developed by IBM in 1997. The electroplating bath solutions are specially formulated by and commercially available from various semiconductor chemical supplier companies. The IC manufacturing electroplating technology, known as superfilling during chip manufacturing has the capability of filling vias having diameters of about 100 nm with a 1:5 aspect-ratio. Such processes, however, are applied globally to an entire chip.
[0010] U.S. Pat. No. 7,674,706 to Gu et al. for “System for Modifying Structures Using Localized Charge Transfer Mechanism to Remove or Deposit Material” (“Gu”) describes depositing a localized drop of electrolyte on a portion of an integrated circuit and depositing or etching using an electric current flowing from a probe in the drop, through the electrolyte and then through the substrate. In one embodiment, the probe in the drop is replaced by using a charged particle beam to supply current, with the circuit being completed through the substrate.
[0011] FIG. 1 shows a method of localized electrochemical deposition of conductors using a micro or nano pipette in close proximity to a conductive surface. Such a method is described in Suryavanshi et al. in “Probe-based electrochemical fabrication of freestanding Cu nanowire array,” Applied Physics Letters 88, 083103 (2006) (“Suryavanshi”). A glass pipette 102 holds an electrolyte solution 104 , such as 0.05 M CuSO 4 . A power supply 106 provides current for the electrochemical reaction, with an electric circuit being formed between a copper electrode 108 and a conductive substrate 110 . The process is typically carried out in atmosphere under the observation of an optical microscope. A device that moves about a surface writing a pattern is referred to as a “nano pen.”
SUMMARY OF THE INVENTION
[0012] It is an object of the invention, therefore, to provide a method for altering a microscopic structure, and in particular, to provide a method for selectively depositing high purity material onto, or removing material from, a microscopic structure
[0013] Embodiments of the invention use a localized charge transfer mechanism to precisely deposit or remove material onto a substrate. In some embodiments, the invention can rapidly and precisely deposit metal conductors or rapidly remove metals or other conductive materials from a structure. Some embodiments use a nanocapillary having a diameter sufficiently small that liquid is extracted by capillary forces, instead of by hydrostatic forces, thereby improving control of the liquid dispensation.
[0014] In some embodiments, the electrochemical reaction is performed in a vacuum chamber of a charged particle beam system, such as an environmental scanning electron microscope, with a moveable nano pen defining a pattern or spot at or near which the deposition occurs. In some embodiments, the surface on which the material is deposited does not need to be electrically conductive—the electrical circuit can be completed, for example, by a charged particle beam or by a thin film of liquid that extends a significant distance from the bubble of electrolyte at the end of the nano pen.
[0015] Some embodiment provide an automated process, with the position and/or the state of the deposit being monitored, preferably by a scanning electron microscope, the image being analyzed by software and the nano pen movement being adjusted based on the image analysis.
[0016] 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. It should be appreciated by those skilled in the art that the conception and specific embodiments 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
[0017] FIG. 1 shows a prior art electrochemical writing instrument.
[0018] FIG. 2 shows a system for depositing pure metal or etching a metal.
[0019] FIG. 3 is a flow chart showing the operation of the system of FIG. 2 .
[0020] FIG. 4 shows a system that uses a charged particle beam as a virtual electrode.
[0021] FIG. 5 shows a system in which electrodeposition is performed on an insulating surface adjacent a conductor.
[0022] FIG. 6 is a flow chart showing the operation of the system of FIG. 5 .
[0023] FIG. 7 is a photomicrograph of a metal deposited using the system shown in FIG. 5 .
[0024] FIG. 8 shows a system in which a charged particle beam deposits a conductor to be used as an electrode in conjunction with the charged particle beam supplying charge for the reaction.
[0025] FIG. 9 is a flow chart showing the operation of the system of FIG. 8 .
[0026] FIG. 10 shows a system in which a beam causes a deposit from a thin layer of electrolyte away from the electrolyte bubble at the tip of the nanocapillary.
[0027] FIG. 11 is a flow chart showing the operation of the system of FIG. 10
[0028] FIG. 12 is a photomicrograph of a metal deposited using the system shown in FIG. 10 .
[0029] FIG. 13 is a flow chart showing a procedure for forming a nanocapillary.
[0030] FIG. 14A is a diagram of the alignment of the nanocapillary relative to the FIB prior to milling the tip of the nanocapillary to achieve the specific geometry necessary to induce adequate flow.
[0031] FIG. 14B is a diagram of the milling of the nanocapillary.
[0032] FIG. 14C is a diagram of the milling of fiducials on the nanocapillary.
[0033] FIG. 14D is a diagram showing the alignment of a nanocapillary with a surface to locally deposit an electrolyte solution for electrochemical deposition.
[0034] FIG. 14E is a diagram showing a side view of a preferred alignment of a nanocapillary.
[0035] FIGS. 15A and 15B are photomicrographs of a nanocapillary after some of the processing steps described in FIG. 14 . FIG. 15A shows the nanocapillary end after cutting. FIG. 15B shows the nanocapillary of FIG. 15B with fiducial milled on it.
[0036] FIG. 16 is a flow chart showing a procedure for preparing the nanocapillary.
[0037] FIG. 17A-D shows a sequence of steps involved in filling the nanocapillary.
[0038] FIG. 18 shows a modified GIS assembly used to hold a nanocapillary.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0039] In a preferred embodiment, the present invention provides a means to directly deposit or etch conductive material onto a substrate. A nano pen dispenses an electrolyte and an electric current through the electrolyte electrochemically deposits material onto the surface or etches material from the surface. A “nano pen,” as used herein, comprises a device that dispenses small quantities of liquid to “write” or “etch” upon a substrate as the pen moves relative to the surface. Nano pens can comprise, for example, nanocapillaries, nano syringes, nanopipettes, etc.
[0040] Some embodiments of the invention can be used to deposit metals that are substantially pure. Because the metals are pure, they can have resistivities that are forty or more times lower than the resistivities of existing FIB-induced deposition of tungsten and platinum materials, and ten times lower than the resistivity of FIB-induced deposition of copper conductive materials. The resistivities are comparable to those of pure metals, for example less than 100 μΩ-cm, more preferably less than 50 μΩ-cm, even more preferably less than 25 μΩ-cm or less than 10 μΩ-cm, and most preferably less than 5 μΩ-cm. The deposited metals can be greater than 90% (atomic percent) pure, more preferably greater than 95% pure and most preferably greater than 99% pure. Alloys could be deposited using solutions containing multiple metal ion species.
[0041] In some embodiments of the invention, the nano pen operates in the sample vacuum chamber of a charged particle beam system, such as an environmental scanning electron microscope (SEM). Environmental SEMs typically operate with the sample in a chamber at a pressure of between 0.07 and 50 Torr, which is much higher than the pressures in the vacuum chamber of a conventional SEM or FIB, typically less than 10 −5 mbar. A liquid electrolyte used in some embodiments of the invention will raise the pressure in the vacuum chamber, but the higher operating pressure can still be within the operating limits of an environmental SEM. In some embodiments, the sample and/or the nano pen may be cooled to reduce the electrolyte vapor pressure and maintain working pressures in the environmental SEM sample chamber within the operating limits.
[0042] When the process is used in an environmental SEM, the SEM image can be used to position and direct the capillary, manually or automatically, for forming a deposition pattern and for monitoring the growth process with great precision. The high resolution of the SEM facilitates an automated process, in which the position of the nano pen and the material being deposited or etched is observed and interpreted using pattern recognition software. The position of the nano pen and the state of the process, such as the geometry of the deposit or etch, are measured and fed back to the process controller to correct the process in real time, that is, while it is being performed, providing a closed loop feedback system. Such embodiments overcome a limitation of prior art systems, such as that of Suryavanshi, in which the accuracy of the placement of the nano pen is limited by the resolution of an optical microscope.
[0043] Another advantage of operating the invention in a vacuum chamber is that a charged particle beam can induce charge transfer reactions so that the charged particle beam can be used as a virtual electrode. Prior art electrochemical, direct-write processes for directly depositing a material onto a surface are not compatible with insulating surfaces as the insulating surface prevents the electrochemical circuit from being formed. Embodiments of the present invention using a charged particle beam itself as a virtual cathode and a nanocapillary to locally apply the electrolyte allows deposition on an insulating surface.
[0044] Using a virtual electrode facilitates deposition on an insulating surface or on an isolated conductor. For example, an ion beam, such as a beam of gallium, argon, or other ions, can provide positive charges to induce anodic reactions for deposition. An electron beam, depending upon the primary beam energy, may induce either anodic or cathodic reactions. The electron beam supplies negative charges for a cathodic reaction. At lower energies, however, each electron in an electron beam can cause the removal of more than one electron from the species in the anodic region, resulting in a net flow of positive charges into the substrate. Thus, the electron beam may be used to electrodeposit material by providing a net positive charge or to etch material by providing a net negative charge.
[0045] When a charged particle beam is used to induce an electrochemical reaction, the other electrode to complete the circuit is typically provided at the nano pen, either by a wire in the nano pen or a coating on the nano pen. In some embodiments, an electron beam or ion beam can be used with a precursor gas to deposit a conductor to be used as a physical electrode. An electron beam or ion beam can be directed to the deposited conductor as a current source. A pattern can be drawn from the beam-deposited conductor using the nano pen, with the electric circuit being completed through the electrodeposited pattern to the electrolyte and finally through the conductor associated with the nano pen. Such embodiments overcome a limitation of prior art systems, such as that of Suryavanshi, because such embodiments do not require a conductive path from the deposited material through the substrate.
[0046] In other embodiments, the electrochemical circuit can extend from the conductor at the nano pen through the electrolyte and through a conductor in electrical contact with conductors within the work as described, for example, in Gu. For example, if the work piece is an integrated circuit, part of the electrochemical circuit can occur through the conductive layers of the circuit using the circuit's pins or probe touching part of a conductive layer for external connections.
[0047] In some embodiments, the fluid is delivered by capillary forces only, as opposed to hydrostatic pressure. Hydrostatic flow of fluid for localized delivery requires a large diameter at the interface of fluid to vacuum, resulting in large uncontrollable amounts of liquid being delivered. The electrolyte capillary bubble in these types of applications typically has a diameter between 1 μm and 50 μm in low vacuums using pressure driven flows. A smaller diameter of, i.e., about 100 nm is preferred for more precise deposition. When the diameter of a capillary is relatively large, liquid can be easily extracted by applying a pressure differential across the liquid in the capillary, that is, pressure is applied at the back end to push the liquid out of the capillary tip. As the diameter of the tip gets very small, an impractically large hydrostatic pressure would be required to force out the liquid, but the liquid can be extracted using capillary action by contacting the end of the nanocapillary with the substrate surface. Capillary action is caused by a combination of surface tension and adhesion of the liquid to a solid.
[0048] The diameter of the nano pen at which capillary action dominates over hydrostatic pressure for extracting liquid depends on the surface tension of the liquid, on the adhesion between the liquid and the material of which the nano pen is composed, and on the adhesion between the liquid and the material of which the substrate is composed. When the nano pen is composed of borosilicate glass, the liquid is ultrapure water, and the substrate surface is silicon, the diameter of the nano pen is preferably less than 20 μm. more preferably less than 5 μm and most preferably less than 1 μm.
[0049] Some embodiments use capillary forces to define fluid flow in a controlled manner, supply the fluid at a precise location on the surface, and deliver adequately small amounts of electrolyte to the surface. This enables the fluid to flow in a defined and controlled manner upon contact of the nano pen to the surface/substrate. Providing fluid flow only via capillary flow results in: (1) directed flow only upon contact of the nanocapillary to the surface; (2) small amounts of fluid can be delivered; (3) fluid can be supplied at a precise location on the surface (high resolution technique).
[0050] Direct-write processes have been limited to directing the charged particle beam toward the electrolyte solution bubble or just on the periphery of the bubble, as delivered by the nano pen. This has made it difficult to alter microstructures in electrically isolated areas. Applicants have found that deposition can be performed away from the electrolyte solution itself due to a very thin layer of solution that diffuses away from the bubble. Depositions 100 microns or more away from the bubble can be induced by directing a charged particle beam to the thin layer, allowing a pattern to be deposited on an insulting or isolated conducting surface away from the electrolyte bubble. The resolution of such a deposition is determined by the resolution of the charged particle beam and interaction volume of the electron beam in the substrate, rather than by the size of the bubble or the diameter of the nano pen.
[0051] Because the electrolyte is applied locally to plate a small area, no electroplating bath is needed. Most of the work piece remains dry. The specific plating solution used will depend on the application; many electroplating solutions are known in the art. For example, one suitable solution comprises ENTHONE ViaForm® Make-up LA, to which is added 5 ml/L of ENTHONE ViaForm® Accelerator and 2 ml/L ENTHONE ViaForm® Suppressor. The ENTHONE ViaForm® solutions are available from Enthone, Inc., West Haven, Conn. Metals such as Cu, W, Au, Pt, Pd, Ag, Ni, Cr, Al, Ta, Zn, Fe, Co, Re etc and alloys composed of these metals can also be written using the nano pen.
[0052] FIG. 2 shows an embodiment of the invention in which a nanocapillary 202 is used for electrochemical deposition or etching within sample vacuum chamber 204 of a charged particle beam system 206 , such as an environmental scanning electron microscope. Nanocapillary 202 is used to deliver electrolyte solution 208 to a surface 210 . The electrolyte solution forms a bubble 214 on surface 210 . The surface may be hydrophilic or hydrophobic, although preferably hydrophilic. Nanocapillary 202 is attached to a micromanipulator 212 that preferably provides motion in three axes and rotation along the capillary axis. In some embodiments, a modified gas injection system, which is a common accessory in charged particle beam systems, can be used as the micromanipulator. One electrode for electrochemical deposition is provided by a conductive coating 218 on, or a wire (not shown) in or on, nanocapillary 202 . The electrode associated with the nanocapillary is positively biased. In some embodiments, surface 210 is conductive and is connected through the sample substrate 220 or through a surface probe (not shown) to an electrode 224 to provide a second contact for electrochemical processing. In other embodiments, the charged particle beam can function as a virtual cathode or anode, providing charges for the electrochemical reaction.
[0053] A pressure limiting aperture 230 maintains a pressure differential between an electron optical column vacuum chamber 232 and the sample vacuum chamber 204 to reduce dispersion of the primary electron beam 231 by gas molecules. Thus, evaporation of the electrolyte 208 increases pressure in the sample vacuum chamber 204 , but much less so in the charged particle beam optical column vacuum chamber 232 . The sample in some embodiments is preferably cooled, for example, by a cooler 240 , such as a thermoelectric cooler, to increase the relative humidity at the substrate as compared to the bulk of the chamber. In some embodiments, the nanocapillary is also cooled, for example, by a thermoelectric cooler.
[0054] The electrochemical deposition or etching can be observed by the charged particle beam system 206 , in which electron beam 231 scans the region where material is being deposited and secondary electrons 234 are emitted upon impact of electron beam 231 . The secondary electrons 234 are amplified by gas cascade amplification and detected by an electrode 238 , forming an image whose brightness at each point corresponds to the current detected by the electrode 238 . The image can be used to monitor and adjust the progress of the electrochemical deposition or etching to provide real time feedback to an operator. The image can be used to position and guide the nanocapillary 202 during deposition or etch.
[0055] In some embodiments, the deposition or etch can be automated. An image processor 250 uses pattern recognition software to recognize the nanocapillary and the substrate around it. A controller 252 controls the movement of the nanocapillary through micromanipulator 212 in accordance with a predetermined pattern. The image from the electron microscope can provide real time position information for closed loop feedback so that the position of the nanocapillary 202 can be controlled to produce the desired pattern on the surface 210 . The deposition or etch pattern can also be observed to adjust the deposition process, such as the speed of the nanocapillary or the pressure at which the nanocapillary contacts the surface.
[0056] As described above, the diameter is preferably sufficiently small so that the electrolyte is forced out of the nanocapillary by capillary action when the capillary is in contact with the surface, rather than through hydrostatic pressure.
[0057] FIG. 3 is a flowchart showing the operation of the system of FIG. 2 . In step 302 , the nanocapillary is filled with electrolyte as described in more detail below. In step 304 , the nanocapillary and sample are placed in the sample vacuum chamber, the nanocapillary being positioned in a micromanipulator so that it can be oriented, positioned, and moved. The sample is typically placed on a three axis stage. In step 306 , the sample vacuum chamber is evacuated. In step 308 , the nanocapillary is positioned at the beginning of the pattern to be deposited by observing the nanocapillary and the sample with the scanning electron beam. In step 310 , the nanocapillary is moved against the surface of the sample, and the electrolyte begins to flow. In step 312 , concurrent with step 310 , current flows from the positively biased electrode at the nanocapillary through electrolyte to a second electrode provided by a conductive feature on the surface, either preexisting or deposited for this process, or by a charged particle beam. After electrochemical deposition of a pattern using the nanocapillary has commenced, current can flow through the deposited pattern to the conductive feature. As the current flows, material is deposited at the cathodic terminal or etched from the anodic terminal. In step 314 , the nanocapillary is moved to deposit the desired pattern. In step 316 , the position of the nanocapillary and the state of the deposition or etch process is observed using the scanning electron microscope. In step 318 , the image is analyzed and in step 320 , the position of the nanocapillary is adjusted. In decision block 322 , the controller determined whether or not the process is complete. If the process is not complete, the process continues with step 316 .
[0058] FIG. 4 shows a charged particle beam system 402 , similar to that shown in FIG. 2 , except in charged particle beam system 402 , the charged particle beam 231 provides a virtual cathode to allow electrochemical deposition on an insulating surface or onto an electrically isolated conductive surface. By using the charged particle beam, preferably an electron beam, as a virtual electrode, nanocapillary 202 can deposit material onto an insulating surface 404 .
[0059] Capillary bubble 214 of the electrolyte solution 208 forms on the surface 404 . Beam 231 is initially directed at the capillary bubble 214 and functions as a virtual cathode by, for example, providing electrons or ions in the beam current to complete the electrochemical circuit. After a conductive material is deposited and nanocapillary is moved away from its original position, the electron beam can be directed to any point along the deposited conductor. The process for using the system of FIG. 4 is the same process described in the flowchart shown in FIG. 3 .
[0060] FIG. 5 shows schematically an embodiment of the invention in which a beam induces electrochemical deposition on an insulating surface 502 by using a nearby electrically isolated conductive region 504 on a substrate 506 . The conductive surface pre-existing as part of the original device or it can be added, for example, through beam-induced deposition. An electrolyte bubble 214 is placed via nanocapillary 202 to overlap the conductive region 504 and the insulating surface 502 upon which the material is to be electrochemically deposited. A charged particle beam 231 , preferably an electron beam, is directed to a location on the conductive region 504 . The point to which the charged particle beam 231 is directed can be a significant distance away from the electrolyte bubble 214 . In some embodiments, charged particle beam 231 acts as a virtual cathode or current source. The other electrode is provided by a coating 218 or wire (not shown) at the nanocapillary to provide a positive bias relative to the substrate. Power supply 512 shows a connection to the nanocapillary and another connection to substrate 506 . If the conductive region 504 is well isolated, no current will flow through the substrate 506 , and all current for the electrochemical reaction will be supplied by the charged particle beam. Material is then deposited on insulating region 502 through electrochemical deposition. Nanocapillary 202 can be maintained in a stationary position or can be moved to provide a pattern of deposited material. If nanocapillary 202 is maintained in a stationary position, the reaction can continue until the electrochemical cell is emptied of electrolyte or shorted by the growth of the deposited material, i.e. copper dendrite, from the contact pad to the nanocapillary 202 . In general, growth occurs preferentially in the direction of the shortest distance between the capillary and the conductive surface.
[0061] FIG. 6 is a flowchart showing the steps of the embodiment shown in FIG. 5 . In step 602 , the nanocapillary is filled with electrolyte as described in more detail below. In step 604 , the nanocapillary and sample are placed in the sample vacuum chamber, the nanocapillary being positioned in a micromanipulator so that it can oriented, positioned, and moved. The sample is typically placed on a three axis stage. In step 606 , the sample vacuum chamber is evacuated. In step 608 , the nanocapillary is positioned at the beginning of the pattern to be deposited by observing the nanocapillary and the sample with the scanning electron beam. In this embodiment, the pattern is started at the edge of a conductive feature. In step 610 , the nanocapillary is moved against the surface of the sample at the edge of a conductive feature, and the electrolyte begins to flow. In step 612 , concurrent with step 610 , current flows from the electrode at the nanocapillary through electrolyte, through the conductive feature and the circuit is completed by the charged particle beam. After electrochemical deposition of a pattern using the nanocapillary has commenced, current can flow through the deposited pattern to the conductive feature so that the circuit can be completed by the charged particle beam. As the current flows, material is deposited at the cathodic terminal or etched from the anodic terminal. In step 614 , the nanocapillary is moved to deposit the desired pattern. In step 616 , the position of the nanocapillary and the state of the deposition or etch process is observed using the scanning electron microscope. In step 618 , the image is analyzed and in step 620 , the position of the nanocapillary is adjusted. In decision block 622 , the controller determined whether or not the process is complete. If the process is not complete, the process continues with step 616 .
[0062] FIG. 7 shows a SEM image of pure copper dendrite 702 grown using the embodiment shown in FIG. 5 on an insulating surface 704 at the edge of a conductive surface 706 . On average, the growth occurs preferentially in the direction of shortest distance from capillary to electrode.
[0063] FIG. 8 shows a system similar to that of FIG. 6 , in which the conductor that mediates electrodeposition is fabricated by beam-induced deposition. FIG. 8 shows a charged particle beam system 800 that includes a gas injection source 803 having a reservoir of precursor materials for use in beam-induced deposition. Beam-induced deposition can be used to deposit a cathode 802 on an insulating surface 404 . A thin layer of material 806 can then be deposited on top of or extending from cathode 802 by moving the nanocapillary 202 in a desired pattern. A precursor gas suitable for FIB deposition of copper is hexafluoroacetylacetonato Cu(I) trimethyl vinyl silane (CAS 139566-53-3). Thus, a focused ion beam can be used to deposit a conductor to be used as a cathode, and then the electrochemical process can be used to deposit a lower resistivity, purer metallic layer on top of or extending from, the FIB deposited layer. An electron beam can also be used to deposit material. Other suitable deposition precursor gases include tungsten hexacarbonyl (W(CO 6 )) and methylcyclopentadienyl trimethyl platinum. An electrolyte solution 208 is then locally applied using nanocapillary 202 as described with respect to FIG. 2 . A conductor on or in nanocapillary 202 provides one electrode. The electrochemical circuit can be completed by the electron beam 231 impinging on the cathode 802 , conductive probe (not shown) contacted to the cathode, or through the substrate 220 .
[0064] The nanocapillary can be moved in an arbitrary pattern to deposit a conductor, and the beam can be directed to the cathode 802 , to the electrolyte bubble, or to any position on the deposited conductor to complete the electrical circuit.
[0065] FIG. 9 shows a method of using the embodiment described in FIG. 8 . Details that were described with respect to earlier embodiments are not repeated. Step 902 includes applying a physical cathode on an insulating surface, preferably by charged particle deposition. Step 904 includes positioning the nanocapillary so that the electrolyte bubble contacts the physical cathode. In step 906 , the electron beam is directed to the physical cathode, thereby providing current to initiate the deposition reaction. Once deposition starts, the nanocapillary can be moved away from the cathode to draw a pattern of deposition in step 908 . The deposited conductive material provides the electrical connection back to the cathode and completes the electrochemical circuit while the electrolyte is moved away.
[0066] FIG. 10 shows a charged particle beam system 1000 in which electrochemical deposition on an insulating surface 502 can be induced at a position remote from the electrolyte bubble 214 and remote from any conductor on the surface. Applicants have unexpectedly found that a very thin layer of electrolyte solution 1002 diffuses a significant distance from electrolyte bubble 214 but remains continuous enough to complete the electrochemical circuit. An electron beam directed to a position on the electrolyte solution layer 1002 will result in the reduction of the electrolyte component to electrodeposit a material. For example, the beam could reduce Cu 2+ from the thin meniscal layer to deposit copper from the electrolyte, with there still being sufficient electrical contact through the layer to complete the circuit and allow continuation of the reaction.
[0067] The electrolyte solution layer 1002 can be so thin that it may not be visible in a ESEM. The electrolyte solution layer 1002 replenishes itself from the bubble 214 as long as the distance away from nanocapillary 202 is not too great. This embodiment shows that it is not necessary to move a nano-pen to deposit a pattern; moving the beam alone within the thin layer will result in deposition in the desired pattern. Electrolyte solution layer 1002 allows direct write deposition of a conductor to be performed up to a 100 microns away from the electrolyte solution itself. The distance to which the fluid extends may be more than 3 times the diameter of the bubble, more than 7 times the diameter of the bubble, more than 20 times the diameter of the bubble or more than 50 times the diameter of the bubble.
[0068] The maximum distance will depend on the electrolyte, the surface, and the pressure in the sample vacuum and can be determined empirically by a skilled person for specific materials. This embodiment provides high resolution, localized electrodeposition without significant regard to the location and size of the electrolytic solution bubble. It had previously been assumed that the direct-write would need to be performed either by the charged particle beam either penetrating the visible bubble or just on the periphery of the visible bubble. Applicants have found that the deposition can be performed tens to a hundred microns away from the bubble, on an isolated area that would appear to be electrically isolated and not provide an electrochemical pathway.
[0069] FIG. 11 is a flow chart showing a process for using the embodiment of FIG. 10 . Process details that are the same as those shown in FIG. 5 are not shown. In step 1102 , the filled nanocapillary is positioned on an insulating surface, and a thin layer of electrolyte extends over the insulating surface. In step 1104 , a charged particle beam is directed in a pattern over the thin layer of electrolyte.
[0070] FIG. 12 shows an SEM image of a deposition made using the system shown in FIG. 10 . The image shows highly pure copper grains deposited more than 50 microns from an electrolyte bubble located on an oxide film. The deposition in this case is on an isolated chrome film, and the nanocapillary was biased to +7 V.
[0071] In an alternative embodiment that uses the thin layer of electrolyte remote from the bubble, a pattern can be deposited starting from a conductor remote from the capillary bubble. Electron beam 231 can be directed to a point on a conductive region 504 that is contacted by the thin electrolyte solution layer 1002 , remote from the electrolyte bubble 214 , and deposition will occur originating at the conductor. After conductive pattern 1004 deposit begins, electron beam 231 can be directed to a point on conductive pattern 1004 to guide the deposition pattern.
[0072] The electrochemical circuit in this embodiment is completed by coating 218 on nanocapillary 202 or by a conductor associated with the nanocapillary. This embodiment provides for electrochemical deposition at electrically isolated areas where there is no pre-existing conductive pathway. This embodiment eliminates the need to deposit, either by beam-induced deposition by using the nanocapillary, a nearby cathode.
[0073] In still another variation, a negative bias is applied to the electrode at the nano pen in contact with the surface, and material is deposited at the position of the nano pen. The positive terminal can be supplied by a focused ion beam or by electron beam operated so as to eject more secondary electrons than are incident in the primary beam, thereby leaving a net positive charge.
[0074] FIG. 13 is a flowchart showing one method of preparing a nanocapillary for use with the present invention. The starting material can be, for example, a borosilicate tube having an inner diameter of 0.5 mm and having an internal filament to assist filling. Such nanocapillaries are commercially available from Sutter Instruments Company, Novato, Calif. In step 1302 , the nanocapillary is cleaned and baked. In step 1304 , the nanocapillary is heated and pressure is applied along the long axis of the tube to create small tips, preferably less than 100 nm, at the end of the nanocapillary. This step is referred to as “pulling,” which can be performed using commercially available “pullers,” also available from Sutter Instruments Company.
[0075] In step 1306 , the nanocapillary is coated with a conductor. For example, the nanocapillary can be sputter-coated with gold. Before coating, the end of the nanocapillary that was not narrowed is preferably covered, for example, with aluminum foil, to prevent sputtered material from reducing the inner diameter of the tube at the end that will be filled. A specific procedure that has worked efficiently is to coat the nanocapillary for 8 minutes on each of two sides at 15 mA dc magnetron sputter current. Another specific procedure that has worked efficiently also is to coat for 4 minutes on each side with Cu at 15 mA power followed by 6 minutes on each side with Au at 15 mA; in this procedure the Cu serves as an adhesion layer for the Au coating.
[0076] In step 1308 the nanocapillary tip is oriented for cutting the tip using a focused ion beam to create a tip geometry that facilitates flow from the nanocapillary. The preferred nanocapillary tip is cut so that the opening from which the electrolyte flows is parallel to the substrate surface when the nanocapillary is positioned in the nanomanipulator. In some embodiments, the nanocapillary is mounted on a modified gas injection system. In some charged particle beam systems from FEI Company, the assignee of the present invention, a gas injection system can be mounted onto any of several ports on the sample vacuum chamber. The angle of each port to the vertical charged particle beam system axis is fixed. The tip of the nanocapillary is cut at an angle determined by the angle of the port in which it will be mounted. For example, in one system, the nanocapillary is oriented in the micromanipulator such that the capillary axis is oriented 30.4 degrees from the substrate surface, and so the tip is cut at 30.4 degrees from the capillary axis, as shown in FIG. 14D . Because of the configuration of a dual beam, with a vertical SEM column and a FIB column oriented at 57.5 degrees, special fixturing and a tilting stage are useful for cutting the tip at the preferred angle.
[0077] FIG. 14A is a diagram showing how the nanocapillary 1402 is aligned relative to the FIB 1406 prior to milling the tip of the nanocapillary. Nanocapillary 1402 is mounted on stub 1404 , which is angled at 66°. Stub 1404 is tilted −14° so that the nanocapillary is normal to FIB 1406 .
[0078] FIG. 14B is a diagram of the milling of the nanocapillary. The tip of nanocapillary 1402 is first centered in the FIB field of view. The FIB 1406 , whose axis 1410 is oriented perpendicular to the page, is scanned along line 1408 to cut the tip of nanocapillary 1402 to cut the tip at 59.6° to a plane normal to the nanocapillary axis in step 1310 . As the insulating capillary tends to accumulate a static charge that deflects the beam, care must be taken during fabrication of the nanocapillary.
[0079] In step 1312 , a very shallow fiducial mark 1420 comprising two perpendicular lines is milled onto the gold coating of nanocapillary 1402 as shown in FIG. 14C . The fiducial mark 1420 is imaged during operation by the electron microscope and are used to rotationally align the nanocapillary to the substrate surface. One line of the fiducial marks 1420 is centered along the nanocapillary axis and another line is perpendicular to the first line, extending fully over the edge of nanocapillary 1402 from the FIB viewpoint.
[0080] In step 1314 , the nanocapillary is filled with electrolyte as described in more detail below. After filling, the nanocapillary is mounted in a micromanipulator, preferably a modified GIS system, in step 1316 . In step 1318 , the nanocapillary is roughly aligned to the center of the electron beam. In step 1320 , the nanocapillary is rotated in the field of view of the electron beam until in the electron beam image the horizontal line of the fiducial terminates at the center of the nanocapillary as shown in FIG. 14D . In FIG. 14D , the electron beam axis, as shown by marker 1422 , is perpendicular to the page. FIG. 14E is a side view showing the preferred alignment of a nanocapillary with a surface when used to locally deposit an electrolyte solution for electrochemical deposition. In step 1322 , the nanocapillary is lowered to contact the surface in order to initiate the flow of electrolyte onto the surface.
[0081] FIGS. 15A and 15B are photomicrograph of a nanocapillary 1500 having a glass tube 1502 cut at an angle and sputter coated with gold 1504 . FIG. 15A shows an internal filament 1506 to facilitate capillary flow within the nanocapillary. The nanocapillary shown in FIG. 15 has a large diameter 1508 to illustrate the fabrication technique. FIG. 15 B shows a smaller scale image of nanocapillary 1500 with an alignment fiducial 1510 visible.
[0082] After the nanocapillary is formed, it is filled. As described above, some embodiments of the invention use a nanocapillary having a sufficiently small inner diameter that the electrolyte flows by capillary action rather than by hydrostatic pressure. The small diameter of the nanocapillary makes filling difficult because of the surface tension of the liquid filling. Reliable and reproducible capillary flow when the nanocapillary touches the substrate within a vacuum chamber depends on the geometry of the tip of the nanocapillary and adequate filling of the nanocapillary with electrolyte.
[0083] FIG. 16 describes a method for filling a nanocapillary. FIG. 17 illustrates various steps of the process shown in FIG. 16 . FIG. 17 is adapted in part from FIG. 4.3 from “Donnermeyer, A. 2007. Thesis. Scanning ion-conductance microscopy. Bielefeld (Germany): Bielefeld University”. FIG. 17A shows a nanocapillary 1700 , which includes an internal filament 1702 to facilitate filing. In step 1602 , illustrated by FIG. 17B , a fluid 1704 is placed inside the nanocapillary by filling it from the backside using a microloader 1706 . The microloader is a syringe with a tip capable of fitting in the backside of the nanocapillary, where the diameter is about 250 microns. Although the internal filament in the nanocapillary causes some fluid 1704 to travel to the tip as shown by meniscus 1710 in FIG. 17C , much of the fluid remains away from the tip because of the small diameter of the nanocapillary 1700 . Optionally, in step 1604 , the back end of the nanocapillary is sealed with vacuum compatible wax 1708 to prevent the fluid inside the nanocapillary from evaporating into the vacuum from the back end of the nanocapillary. The wax used can be, for example, Apiezon Wax W. Mild heat (approximately 110° C.) can be used to melt the wax and provide a good vacuum-tight seal. The fluid is thus effectively sealed inside the nanocapillary. If wax is not used to seal the back end of the nanocapillary then the metal section 1808 in FIG. 18 (described below) should be sealed to ensure that the fluid is sealed inside the nanocapillary and cannot evaporate via the back side into the vacuum chamber.
[0084] To facilitate filling of the tip of the nanocapillary, it is placed in a customized centrifuge. An example of a customized centrifuge uses a rotor from a 12 V computer fan, model FAN 3701U from StarTech. In step 1606 , the centrifuge is operated, for example, at 5000 rpm for 30 minutes, which is sufficient for reproducible and reliable filling of the nanocapillary tip with fluid. FIG. 17D shows the nanocapillary after step 1606 showing the additional fluid at the tip as shown by the movement of meniscus 1710 . In step 1608 , the nanocapillary is attached to the micromanipulator. Good electrical contact between the conductive coating on the nanocapillary and the metal of the micromanipulator can be provided by applying silver paint to the junction. The drying of the silver takes about 10-20 minutes, and two layers are typically applied. The nanocapillary is then ready for use. The flow from the nanocapillary to the substrate or surface is primarily due to capillary forces, and as such, the tip of the nanocapillary contacts the substrate directly to induce a flow.
[0085] In step 1610 , nanocapillary 1402 in the micromanipulator is aligned to the center of an electron beam. In step 1612 , nanocapillary 1402 is rotated to locate the fiducial marks 1420 , and the nanocapillary is oriented so that the horizontal fiducial line terminates at the center of nanocapillary 1402 as viewed with the electron beam. Nanocapillary 1402 is then ready to locally deliver fluid to the substrate 1430 in step 1614 .
[0086] Because many charged particle beam systems include a gas injection system (GIS) for beam induced deposition and etching, and the gas injection system typically has the movement capabilities required for the nanocapillary, it is convenient to attach the nanocapillary to an existing GIS. FIG. 18 shows a modified GIS assembly 1800 that provides the necessary positioning capability. That is, the modified GIS assembly includes the ability to insert, to retract, to rotate, and to adjust the position of the inserted nanocapillary. The modified GIS housing mounts to the wall of the vacuum chamber walls at a known angle, so the nanocapillary is inserted at a well defined angle with respect to the surface.
[0087] Modified GIS assembly 1800 includes metal rod 1802 which spans the entire length of GIS 1810 . One end of metal rod 1802 includes a handle 1806 to provide easy rotational, insertable, and retractable movement of the nanocapillary for in chamber applications. The vacuum seal of metal rod 1802 is provided by a series of small o-rings 1804 spaced along the length of metal rod 1802 . The vacuum seal has been shown to work down to chamber pressures of 2×10 −6 mbar, and it is still possible to rotate central rod 1802 at this vacuum level without causing a gas burst or leak.
[0088] A nanocapillary 1807 is attached to an intermediate metal section 1808 . A silicone o-ring 1805 can be used to hold the metal section 1808 to provide a vacuum seal. The intermediate metal section 1808 screws into rod 1802 .
[0089] Preferably, metal rod 1802 is electrically isolated from the shell of GIS assembly 1810 to allow an electrical bias to be applied to the nanocapillary. This is useful in cases where the nanocapillary functions as the anode or cathode in electrochemical circuits. If the nanocapillary is to be grounded to the chamber, a simple grounding connection can easily be made.
[0090] Some embodiments, such as the automated deposition aspect using pattern recognition software and feedback, can be practiced in air, outside a vacuum chamber. Embodiments that use a charged particle beam are practiced within a vacuum chamber used for charged particle beam processing. Some embodiments that are practiced within a vacuum chamber use an electrolyte having low or negligible vapor pressure, such as a neoteric liquid, while other embodiments use a convention, higher vapor pressure electrolyte.
[0091] Using an embodiment suitable for use within a charged particle beam vacuum chamber allows steps that require charged particle beam processing and steps that require electrochemical processing to be performed without repeatedly moving the work piece into and out of a vacuum chamber. Such embodiments eliminate the time consuming steps of moving the work piece in and out of the vacuum chamber and pumping down the vacuum chamber to an adequate vacuum between process steps. Also, maintaining the work piece within a vacuum chamber reduces contamination.
[0092] Because any conductive area within the electrochemical circuit and covered by the electrolyte will be affected by the electrochemical reaction, it is desirable in some applications to provide a barrier which insulates any exposed conductive area within the circuit that is to remain unaffected. A local insulating layer can be deposited using electron-beam-induced deposition, FIB deposition, chemical vapor deposition, or another process. The electrochemical process will not deposit or etch the work piece where protected by an insulating layer.
[0093] Embodiments of the invention are applicable to various aspects of nanotechnology, including “device editing,” that is, adding or removing electrical paths to change the connections in a device such as an integrated circuit. Embodiments of the invention are useful in any application that requires precise localized deposition or etching of metals and other materials.
[0094] Also, the technique is not necessarily limited to depositing and etching conductors—charge transfer may also be used to deposit or remove polymer materials. The local electrochemical processes can be used on any surface to which an electrolyte can flow, and it is not limited, like beam processing, to processing along a line of sight from the beam source.
[0095] The term “contact” or “electrical contact” as used herein includes direct and indirect connections. While the invention is described primarily in terms of depositing or etching metals, the invention can be used to deposit or etch any material having sufficient conductivity to participate in electrochemical reaction.
[0096] The invention has multiple aspects that are separately patentable and not all aspects will be used in all embodiments.
[0097] 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. The scope of the present application is not limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.
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A charge transfer mechanism is used to locally deposit or remove material for a small structure. A local electrochemical cell is created without having to immerse the entire work piece in a bath. The charge transfer mechanism can be used together with a charged particle beam or laser system to modify small structures, such as integrated circuits or micro-electromechanical system. The charge transfer process can be performed in air or, in some embodiments, in a vacuum chamber.
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BACKGROUND OF THE INVENTION
The present invention is directed to a strain gage bridge circuit with sensitivity equalization and method for sensitivity equalization that are improvements over an invention disclosed in U.S. Pat. No. 4,979,580, issued Dec. 25, 1990 to Lockery, the contents of which patent are incorporated herein by reference.
U.S. Pat. No. 4,979,580 to Lockery discloses how to equalize the measuring sensitivity of opposing half-bridges in a strain gage bridge circuit by connecting pairs of shunt resistors of equal resistance cross a pair of bridge arms forming one half-bridge, and describes how this equalization method can be used to eliminate the sensitivity to variations in the location of the point of force application in a planar weighing device with four strain gages. Changes in the shunt resistance affects the sensitivity of one side of the load platform only, and does not affect the zero adjustment of the bridge output signal. The sensitivity adjustment method described in U.S. Pat. No. 4,979,580 to Lockery works well, and it has been used extensively. Sensitivity adjustment is usually done by trial and error, with resistor decade boxes used as shunt resistors. The resistor boxes are replaced with soldered-in combinations of fixed resistors before the load cell is shipped. Accurate replacement of the resistor box values, however, is a rather demanding and time consuming procedure, especially since the two resistors in a pair must always remain exactly equal. The shunt resistor values also affect the adjustments for linearity and temperature compensation in the strain gage bridge circuit.
SUMMARY OF THE INVENTION
A main object of the present invention is to provide an inexpensive strain gage bridge circuit with equalization of the relative sensitivity of opposing half-bridges in the strain gage bridge circuit.
A further object of the present invention is to provide a method for adjusting the relative sensitivity of opposing half bridges in a strain gage bridge circuit that is easier and less time consuming to perform than previously known methods.
A still further object of the present invention is to provide a sensitivity equalization method that is particularly suitable for load cell devices and that is as effective and accurate as the method described in U.S. Pat. No. 4,979,580, but which does not cause any interaction between the sensitivity adjustment and the adjustments for linearity or temperature compensation in a load cell device utilizing a strain gage bridge circuit according to the invention.
A strain gage bridge circuit, according to a preferred embodiment of the present invention, comprises four arms including strain gages to form two pairs of opposing half bridges arranged symmetrically with respect to two bridge diagonals, first and second resistors connected in series across a first diagonal of the bridge circuit, and a third resistor connected between one end of a second bridge diagonal and the junction point of the series connected first and second resistors.
A method, according to a preferred embodiment of the invention, for sensitivity equalization of opposing half-bridges in a strain gage bridge circuit having four arms forming a first and a second bridge diagonal and pairs of half-bridges arranged symmetrically about each of the first and second bridge diagonal comprises the steps of connecting a pair of substantially equal resistors in series across a first diagonal in the bridge circuit, determining which of the two half-bridges arranged symmetrically about the first bridge diagonal has the highest sensitivity, connecting a third resistor between the junction point of the series-connected resistors and an end point of the second diagonal forming a center tap on the half-bridge having the highest sensitivity, and adjusting the resistance of the third resistor to equalize the sensitivity of the two half bridges about the first bridge diagonal.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate a preferred embodiment of the invention and, together with the description, serve to explain the principles of the invention.
FIG. 1 is a schematic diagram of a strain gage bridge circuit, according to a preferred embodiment of the present invention, with two sets of three equalization resistors.
FIG. 2 is a schematic diagram of the same strain gage bridge circuit as in FIG. 1, after a Y-Δ transformation of the three-resistor network in each set of equalization resistors.
FIG. 3 is a schematic diagram of a known strain gage bridge circuit with equalization resistors for two half-bridges as described in U.S. Pat. No. 4,979,580 to Lockery.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made in detail to a preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.
According to the preferred embodiment of the invention, FIG. 1 shows a strain gage bridge circuit with a strain gage bridge 40 having four arms 41, 42, 43, 44, each including at least one strain gage. One diagonal, with end points A-B, is connected to a power supply source 50 in series with resistor device 45', 45" serving to compensate for temperature variations and non-linearity in the strain gage bridge 40, as is known in the art. The second diagonal, with end points C-D, provides an output signal representing the sum of the signals generated by the strain gage device in the four arms 41, 42, 43, 44, and is connected to an indicator 51.
In many load cell applications, opposing half-bridges, 41-42 and 43-44, or 41-43 and 42-44, will have different sensitivities to an applied load, e.g. as described in U.S. Pat. No. 4,979,580 to Lockery, which is included herein by reference. According to the preferred embodiment of the present invention, resistor networks 71', 71", 72 connected to bridge terminals A, B, D, and 73', 73", 74 connected to bridge terminals C, D, B, are added to the basic strain gage bridge 40 as shown in FIG. 1 for the purpose of equalizing such sensitivity differences. First and second resistors 71' and 71", which have substantially equal resistance values, are connected in series across bridge diagonal A-B, and a third resistor 72 is connected between the junction point between the series connected first and second resistors 71', 71" and junction point D between bridge arms 43, 44. In the same way, fourth and fifth resistors 73', 73", which also have substantially equal resistance values, are connected in series across bridge diagonal C-D, and a sixth resistor 74 is connected between the junction point between the series connected resistors 73', 73" and junction point B between bridge arms 42, 44.
How the two resistor networks 71', 71", 72 and 73', 73", 74 can be used to change the sensitivity of the associated half-bridges will be best understood by reference to FIG. 2, which shows the same circuit as FIG. 1, except that the two Y-connected resistor networks 71', 71", 72 and 73', 72", 74 have been transformed to their equivalent A-configurations.
It is known to those skilled in the art that any impedance network with three terminals can be represented by either a Y or a Δ configuration of three impedances, and it makes no difference to external circuits which of the two representations is selected. Textbooks on electrical circuits give the following formulae for the transformation of resistance values from a Y configuration, such as 71', 71", 72 in FIG. 1 to an equivalent Δ configuration, such as 81', 81", 82 in FIG. 2:
R81'=(R71'*R71"+R71'*R72+R71"*R72)/R71" (1)
or:
R81'=R71'+R72(1+R71'/R71") (1a)
R81"=((R71'*R71"+R71'*R72 +R71"*R72)/R71' (2)
or:
R81"=R71"+R72(1+R71"/R71') (2a)
R82 =(R71'*R71"+R71'*R72+R71"*R72)/R72 (3)
If one sets R71'=R71"=R71, then:
R81"=R71+2R72 (1b)
R81'=R71+2R72 (2b)
R82=R71 (2+R71/R72) (3b)
Transformation of resistance values 73', 73", 74 in the second Y resistor network to an equivalent Δ resistor network 83', 83", 84 follows the same formulae, with 73, 74 replacing 71, 72 and 83, 84 replacing 81, 82.
FIG. 3 shows the bridge connection and equalizing resistors for the force measuring device described in U.S. Pat. No. 4,979,580. Resistors 81' and 81" in FIG. 2 affect the sensitivity of half bridge 43, 44 in a similar way as resistors 61', 61" affect the sensitivity of half bridge 43, 44 in FIG. 3.
Considering that FIGS. 1 and 2 are equivalent, with equations (1b)-(3b) determining the relationships between the resistors 81', 81", 82 and resistors 71', 71", 72, it will be understood that it is possible to vary the effective shunting of bridge arms 43 and 44 by varying a single resistor 72 in the arrangement shown in FIG.1. The third resistor 82 in FIG. 2 does not affect the sensitivity of any bridge arms, but simply acts as a load on the bridge diagonal A-B,
Resistor network 73', 73", 74 affects half bridge 42, 44 exactly the same way as resistor network 71', 71", 72 affects the half bridge 43, 44. The conversion formulae are the same, only with 73 replacing 71, 74 replacing 72, 83 replacing 81, and 84 replacing 82 everywhere.
Formulae (1b)-(3b) show that the effective shunt resistance values R81'=R81"=R81 can be varied in the range R71≦R81≦∞ by changing R72 from 0 to ∞. R71' and R71" can thus be pre-selected fixed resistors having resistance values low enough to permit maximum anticipated change in sensitivity for a half bridge while the actual adjustment is made by one single resistor 72. The effective shunt resistance values 81' and 81" will always remain equal, independent of the resistance value R72. This makes it possible to use a potentiometer for R72 instead of resistor decade boxes, so the equalization process will be much simpler and less time consuming than equalization by the method described in U.S. Pat. No. 4,979,580.
In practice, equalization according to a preferred embodiment of the invention is done as follows:
First, a pair of fixed resistors having equal resistance values (typically 20 kohm each for a strain gage bridge based on 350 ohm gages) are connected in series across each of the two bridge diagonals A-B and C-D. Next, the weighing or force measuring device, e.g. a load cell device, including the strain gage bridge 40 is loaded at different points of load application, and notice is made of which half bridges have the highest sensitivities. Variable resistors, e. g. potentiometers (typically 0-500 kohm), are next connected between each center point of the two series-connected resistors and the center point of each most sensitive half bridge, such as D and B in FIG. 2. A load is then moved across the weighing device, while the variable resistors are adjusted until the output signal remains constant while the load is moved. If potentiometers were used as variable resistors, they may be left in the circuit, or they can be replaced by soldered-in resistor combinations. As long as the two series-connected resistors 71' and 71" are equal, the two arms in the equalized half bridge will be guaranteed an equal amount of shunting, as shown by formulae (1b) and (2b), so the equalization will not affect the zero balance of the bridge circuit.
It can also be shown from equations (1a) and (2a) that the ratio of the effective shunt resistors 81' and 81" will remain equal to the ratio of resistors 71' and 71" even when these are not equal. This may be useful in certain cases when the two arms in a half bridge are slightly unequal, because resistors 71', 71" and/or 73', 73" can be selected to match the slight deviation from equal ratio exhibited by bridge arms 43, 44 and/or 42,44, thereby ensuring constant zero balance during the equalization process even in such a case.
The circuit shown in FIGS. 1 and 2 has another advantage over the known circuit according to FIG. 3. The resistance values R82 and R84 in FIG. 2 load the bridge diagonals A-B and C-D, and it can easily be calculated that these resistance values compensate for changes in the load from the resistors 81' and 81", respectively 83' and 83" on the bridge diagonal, so the total load on the bridge diagonals A-B and C-D remains independent of the amount of equalization. This fact can also be seen directly, without calculation, from FIG. 1. When the bridge 40 is balanced, resistors 72, 74 are each connected between points with equal potentials, so no current flows in these resistors. The total load on bridge diagonals A-B and C-D is thus determined solely by the fixed series-connected resistors 71', 71", respectively 73', 73". Only when strains in the load cell causes the resistance of bridge arms 41-44 to change so the bridge becomes unbalanced will current flow in resistors 72, 74. Resistors 72 and 74 will thus affect the sensitivity of the bridge arms, even though they do not affect the total load on the bridge diagonals. The constant load on the bridge diagonal A-B ensured by the preferred embodiment of the present invention as described makes certain that changes in equalization adjustment do not cause any change in the voltage drop in resistors 45', 45", which control temperature compensation and/or non-linearity in the strain gage device. The load across diagonal C-D is similarly constant, which ensures that changes in equalization adjustment do not change the output impedance of the bridge.
It will be evident to those skilled in the art from this description of the above preferred embodiment that only one set of sensitivity adjusting resistor network (71', 71", 72 or 73', 73", 74) will be required in those cases where only one pair of bridge arm has a sensitivity imbalance. In these cases, shunt resistors (71', 71"or 73', 73") may be connected across either diagonal A-B or diagonal C-D, as required, while the other set is left out of the circuit. Alternatively, both pairs of fixed shunt resistors (71', 71" and 73', 73") may be included as standard in the bridge circuit at all times, but one of the variable value resistors (72, 74) may be left open in some cases, as determined during calibration of the load cell.
It will also be evident to those skilled in the art from this description of the preferred embodiment that the usefulness of the present invention is not limited to planar weighing devices, as described in U.S. Pat. No. 4,979,580. Embodiments of the invention can be applied to any load cell or load cell system where accurate equalization of sensitivity between individual gages is required.
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A strain gage bridge circuit and method for sensitivity equalization, particularly suitable for load cell devices for precision measurement. The sensitivity of opposing half-bridges in a strain gage bridge circuit is equalized by a pair of equal, fixed resistors connected across a bridge diagonal formed by the two half-bridges, and a third resistor connecting the junction of the two equal, fixed resistors to the center of the half-bridge with the highest sensitivity. The effective shunting of the most sensitive half bridge can be changed by changing the value of the third resistor, while the ratio of the two equivalent shunting resistance values remain exactly constant. The total load on the bridge diagonal also remains constant when the value of the third resistor is changed. Both sets of orthogonally arranged opposed half-bridges in a strain gage bridge circuit can be equalized independently when two sets of equalizing resistors are used.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional of U.S. Ser. No. 12/575,070, entitled “Modular Three-Dimensional Chip Multiprocessor,” filed Oct. 7, 2009, which is a divisional of U.S. Ser. No. 11/706,742, entitled “Modular Three-Dimensional Chip Multiprocessor,” filed Feb. 14, 2007. Both applications are hereby incorporated by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present application relates generally to processors and memory for computer systems.
[0004] 2. Description of The Background Art
[0005] Conventional two-dimensional (2-D) microprocessors, including conventional chip multiprocessors, are formed on a single silicon die. In order to increase performance of these microprocessors, further components, such as more processor cores, caches and memory controllers, are generally being integrated into the single silicon die.
[0006] Recently, however, technologies for stacking of silicon die have been developed. In order to apply the stacking technologies to chip multiprocessors, various proposals have been made. Each of these proposals provide an architecture or design for implementing the chip multiprocessor on a stack of silicon dies. For example, one set of proposals splits each core of the chip multiprocessor between multiple stacked die.
[0007] Applicants have observed that each of the proposals for applying stacking to chip multiprocessors makes the natural assumption that stacking will be required. In other words, the designs are optimized assuming stacking of silicon dies.
SUMMARY
[0008] One embodiment relates to a chip multiprocessor die supporting optional stacking of additional dies. The chip multiprocessor includes a plurality of processor cores, a memory controller, and stacked cache interface circuitry. The stacked cache interface circuitry is configured to attempt to retrieve data from a stacked cache die if the stacked cache die is present but not if the stacked cache die is absent. In one implementation, the chip multiprocessor die includes a first set of connection pads for electrically connecting to a die package and a second set of connection pads which can be configured for communicatively connecting to the stacked cache die if the stacked cache die is present.
[0009] Other embodiments, aspects, and features are also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A is a schematic cross-sectional diagram depicting a modular (stackable) chip multiprocessor with a variable number of stacked die for high-performance system applications in accordance with an embodiment of the invention.
[0011] FIG. 1B is a schematic planar-view diagram depicting two sets of contact pads for a modular chip multiprocessor having at least one stacked die in accordance with an embodiment of the invention.
[0012] FIG. 2A is a schematic cross-sectional diagram depicting a modular chip multiprocessor without any stacked die for low-cost system applications in accordance with an embodiment of the invention.
[0013] FIG. 2B is a schematic planar-view diagram depicting two sets of contact pads for a modular chip multiprocessor having no stacked die in accordance with an embodiment of the invention.
[0014] FIG. 3 is a schematic diagram showing an example logic design for a modular 3-D chip multiprocessor in accordance with an embodiment of the invention.
[0015] FIG. 4 is a flow chart of a method performed by a memory controller of a modular 3-D chip multiprocessor in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0016] The present application discloses an architectural design for a chip multiprocessor die in embodiments of the present invention, where the chip microprocessor die is configured to be modular in that the 3-D stacking of additional levels of cache memory is optional, i.e. possible but not required. In this architecture, all the cores are contained on a single processor die. Additional cache levels may be optionally stacked using additional die.
[0017] FIG. 1A is a schematic cross-sectional diagram depicting a modular (stackable) chip multiprocessor with a variable number of stacked die for high-performance system applications in accordance with an embodiment of the invention. In this embodiment, the chip multiprocessor (CMP) die 102 includes the multiple processor cores and one or more of near cache levels.
[0018] The heat sink 104 may be advantageously attached to the chip multiprocessor die 102 , and the package 106 (including connectors 108 for power and input/output) is preferably attached to at least one stacked cache die (for example, the topmost stacked die 110 - 2 in the illustrated example), if any. Of course, while the CMP 102 , stacked cache die 110 , and package 106 are shown spaced apart in FIG. 1 for purposes of depicting the stacking order, an actual implementation would not typically have the spacing between the components. Instead the stacked cache die 110 would be stacked directly on top of the CMP 102 , and package 106 would be configured on top of the stacked cache die 110 .
[0019] FIG. 1B is a schematic planar-view diagram depicting two sets of contact pads for a modular chip multiprocessor having at least one stacked die in accordance with an embodiment of the invention. Note that the particular arrangement, shape and scaling of the contact pads shown in FIG. 1B are arbitrary for purposes of explanation.
[0020] As shown in FIG. 1B , the contact layer of the base die 102 for the chip multiprocessor is preferably configured to have two sets of connection pads. A first set of pads 120 preferably includes pads with larger surface areas and may either be connected directly to a package 106 or routed through one or more stacked die 110 to a package 106 . The interconnections from this first set of connection pads are shown by the thicker lines 112 in FIG. 1A . A second set of pads 130 preferably include pads having smaller surface areas and would preferably only be used for communicating with stacked die 110 if they were present in the system. The interconnections for these connection pads are shown by the thinner lines 114 in FIG. 1A .
[0021] FIG. 2A is a schematic cross-sectional diagram depicting a modular chip multiprocessor without any stacked die for low-cost system applications in accordance with an embodiment of the invention. In this embodiment, the base die of the chip multiprocessor 102 is present, but the stacked cache die 110 are absent. As such, the thicker interconnections 112 to the package 106 are used, but there are no thinner connections 114 to the absent stacked cache die 110 .
[0022] FIG. 2B is a schematic planar-view diagram depicting two sets of contact pads for a modular chip multiprocessor having no stacked die in accordance with an embodiment of the invention. Note again that the particular arrangement and scaling of the contact pads shown in FIG. 2B are arbitrary for purposes of explanation.
[0023] As shown in FIG. 2B , the contact layer of the base die for the chip multiprocessor 102 is again configured to have two sets of connection pads. The first set of pads 120 preferably includes pads with larger surface areas and may be connected directly to a package 106 . The interconnections from this first set of connection pads are shown by the thicker lines 112 in FIG. 2A . The second set of pads 130 preferably include pads having smaller surface areas and would preferably only be used for communicating with stacked die 110 if they were present in the system. In this case, however, there are no (optional) stacked die 110 present. Hence, the second set of pads 130 remain unconnected and un-used.
[0024] Advantageously, using this architectural design, the number of stacked cache die 110 is variable. In the particular implementation shown in FIG. 1A , two stacked cache die 110 - 1 and 110 - 2 are shown. This implementation may correspond to a high-performance high-cost multiprocessor system for applications with large memory needs. On the other hand, in the particular implementation shown in FIG. 2A , no stacked cache die 110 are shown. This implementation may correspond to a lower-performance lower-cost multiprocessor system for applications with smaller memory needs.
[0025] Furthermore, this architectural design advantageously positions the cores, which typically dissipate the vast majority of power and hence generate the most heat, nearest to the heat sink 104 and the optional stacked cache die, which typically generate much less heat, further from the heat sink 104 .
[0026] An example logical design for a chip multiprocessor 102 in accordance with an embodiment of the present invention is illustrated in FIG. 3 . While a particular CMP design (i.e. one with private L1 caches, semi-private L2 caches, and a shared L3 cache) is shown in FIG. 3 , other specific CMP designs may be utilized in accordance with other embodiments of the invention.
[0027] As shown in FIG. 3 , the chip multiprocessor 102 includes multiple processor cores 302 . Level one instruction (L1I) and level one data (L1D) caches may be provided for each core 302 . In this particular implementation, semi-private level two (L2) caches 304 are each shared by two cores 302 . Further in this particular implementation, inter-core interconnect circuitry 306 interconnects the L2 caches with a shared level 3 (L3) cache 308 . The shared L3 cache 308 is shown divided into banks.
[0028] As further shown in FIG. 3 , one or more memory controllers 310 on the chip multiprocessor die 102 may be configured to communicate by way of the relatively thicker conductive connections 112 which interconnect those contact pads 120 with input/output connections (see 108 ) of the package 106 . The one or more memory controllers 310 also connect to stacked cache interface circuitry 312 which is on the CMP die 102 . While one block of circuitry is depicted in FIG. 3 for the stacked cache interface circuitry 312 , the stacked cache interface circuitry 312 may comprise one block or multiple blocks of circuitry. The stacked cache interface circuitry 312 may be configured to communicate by way of the relatively thinner conductive connections 114 which interconnect those contact pads 130 with the optional stacked cache die 110 .
[0029] The stacked cache interface circuitry 312 may be small and so may be implemented without adding much cost to the CMP die 102 in the case where the CMP die 102 is not stacked (i.e. where no stacked cache die 110 are used and there are no stack die connections 114 ). Also, power to the stacked cache interface circuitry 312 may be configured so as to be unconnected in the case where the CMP die 102 is not stacked.
[0030] The memory controllers 310 may be configured to signal the stacked cache interface circuitry 312 so as to find out if one or more stacked cache die are present or if there are no stacked cache die. The stacked cache interface circuitry 312 may be configured to detect the presence of the optional stacked cache (e.g., a level 4 cache) die 110 by several mechanisms. One such mechanism comprises receiving a reply (acknowledgement signal) to signals transmitted to the stacked cache die 110 to indicate presence of the stacked cache die 110 or not receiving a reply to such signals which would indicate an absence of the stacked cache die 110 . Another mechanism comprises an absence of a signal path due to a lack of stacking (i.e. the signal path is open circuit when there is no stacked cache die 110 ).
[0031] FIG. 4 shows a logical method 400 performed by a memory controller 310 of a chip multiprocessor 102 in accordance with an embodiment of the invention. As shown by the branch point 401 , processing of a memory request is different depending on whether or not at least one stacked cache die is present. In accordance with an embodiment of the invention, the determination 401 as to whether one or more stacked cache die is present or absent may be performed at power-up by the memory controllers 310 . For example, in accordance with one embodiment of the invention, power to the stacked cache interface circuitry 312 may be disconnected during manufacture of the die 102 if there are no stacked cache die to be included in the system. In that case, the presence or absence of power to the stacked cache interface circuitry 312 may be used by the memory controllers 310 as an indication of the presence or absence of stacked cache die.
[0032] The memory controller 310 receives 402 a memory request. If no stacked cache die is present, then the memory controller 310 fetches 406 the requested data from the main memory (for example, from the memory DIMMs). In other words, in the lower-performance lower-cost configuration shown in FIG. 2A , the memory controller 310 on the chip multiprocessor 102 accesses main memory for the missing data.
[0033] On the other hand, if there is a stacked cache (i.e. if there is one or more cache die) 110 , then the memory controller 310 attempts to find the data in the stacked cache 110 by sending 408 a memory request signal to the stacked cache interface circuitry 312 . If 410 the data is found in the stacked cache (i.e. a stacked cache hit), then the memory controller 310 receives 412 the requested data from the stacked cache interface 312 . If the data cannot be found in the stacked cache (i.e., a stacked cache miss), then the memory controller 310 resorts to fetching 406 the data from memory.
[0034] In accordance with one embodiment, the chip multiprocessor die 102 includes one or more near cache levels, and the stacked cache die(s) 110 include optional cache levels which are higher (farther) than those levels on the chip multiprocessor die 102 . In that case, memory requests would be processed by first checking the near cache levels on the CMP die 102 . Upon near cache misses such that the data requested is not found on the CMP die 102 , the memory controller 310 would then send a memory request signal to the stacked cache interface circuitry 312 . If the data is found in the stacked cache (i.e. a stacked cache hit), then the memory controller 310 receives 412 the requested data from the stacked cache interface 312 . If 410 the data cannot be found in the stacked cache (i.e., a stacked cache miss), then the memory controller 310 resorts to fetching 406 the data from memory.
[0035] The architecture disclosed in the present application has several advantages or potential advantages. First, processor manufacturers are generally interested in providing a range of products to cover different markets. However, designing different products for different markets is typically rather expensive. Instead, with optional stacking, manufacturers may sell a stacked chip microprocessor in markets that had higher performance demands and required a more powerful memory system (e.g., enterprise servers and high-performance computing applications), while the base die may be used in lower-performance cost-sensitive applications (e.g., home consumer and laptop applications). The lower-performance lower-cost version of the product may be built simply by omitting some or all of the stacked die.
[0036] Second, by placing all the cores on a single die, this architecture produces a low thermal resistance between the cores and the heat sink. Since the cores dissipate the vast majority of the power, this yields the lowest operating temperature (i.e. most efficient heat sinking) for the stack as a whole.
[0037] In the above description, numerous specific details are given to provide a thorough understanding of embodiments of the invention. However, the above description of illustrated embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise forms disclosed. One skilled in the relevant art will recognize that the invention can be practiced without one or more of the specific details, or with other methods, components, etc. In other instances, well-known structures or operations are not shown or described in detail to avoid obscuring aspects of the invention. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize.
[0038] These modifications can be made to the invention in light of the above detailed description. The terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification and the claims. Rather, the scope of the invention is to be determined by the following claims, which are to be construed in accordance with established doctrines of claim interpretation.
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A chip multiprocessor die supports optional stacking of additional dies. The chip multiprocessor includes a plurality of processor cores, a memory controller, and stacked cache interface circuitry. The stacked cache interface circuitry is configured to attempt to retrieve data from a stacked cache die if the stacked cache die is present but not if the stacked cache die is absent. In one implementation, the chip multiprocessor die includes a first set of connection pads for electrically connecting to a die package and a second set of connection pads for communicatively connecting to the stacked cache die if the stacked cache die is present. Other embodiments, aspects and features are also disclosed.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/755,114, filed Jan. 22, 2013, the content of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to orthopedic braces and more particularly to orthopedic braces with micro-adjustable telescoping arms.
BACKGROUND OF THE INVENTION
[0003] There are many forms of orthoses, or devices used externally to modify the structure and/or function of the skeletal and/or neuromuscular systems of the body. For example, there are orthoses that are applied to the neck, to the spine, to the upper limbs, and to the lower limbs. Additionally, there are many different purposes for using orthoses ranging from rehabilitative, to prophylactic. Rehabilitation braces are typically used to limit the movement of the portion of the body following an injury or a surgery.
[0004] Certain rehabilitation braces, for example orthopedic knee braces, typically immobilize the leg and/or limit the motion in both the lateral and medial directions. These braces provide a mechanism to reduce the range of motion for a healing limb. The ability to limit flexion and extension are important features for an effective orthopedic knee brace. To maximize the benefits of an orthopedic brace it must be properly fitted and adjusted to the patient. Adjustment variables include fitting patients of various sizes and body proportions, and accommodating a variety of possible surgical sites. The adjustment of the brace will also be continual as the patient heals and can tolerate larger ranges of motion, as swelling is reduced, and the like. At times there may also be readjustment of the braces paddles to adapt accessories and product upgrades.
[0005] To accomplish adjustability in existing orthotic braces, some brace designs utilize a system of holes in the strut. For example, in U.S. Pat. No. 6,821,261 a series of holes incorporated into the brace's strut is disclosed. This system of holes allows support members to be adjusted into a small number of positions on the patient. The holes disclosed in the aforementioned patent slide over a button and a biasing spring forces the button into the respective hole at a particular position. The operator, or physician, must depress the button in order to advance to the next available hole. This is done repeatedly until the closest available length is achieved. One problem with this method is that the notched holes where the locking feature, or button, can engage are grossly separated along the strut, and thus, only provide for gross adjustment of the lengths of the orthopedic brace. In the case of a knee brace, there would be a need to adjust both the upper and lower lengths of the brace (as described in reference to the hinge element). Other orthopedic braces may have additional areas where the length needs to be adjusted, further compounding the gross adjustment issue.
[0006] Similarly, in U.S. Pat. No. 7,384,406 B2, a series of notches incorporated into the brace's strut is disclosed. This system of notches, just as in the previous system, allows support members to be adjusted into a small number of positions ort the patient. The notches disclosed in this system are engaged by a screw with a biasing spring and a retaining bushing. The biasing spring pushes a button in an upward position. By depressing the same button, the spring pushes the retaining bushing out of a particular notch. With pressure still applied, the length of the portion of the brace is adjusted to the next available notch and the retaining bushing re-engages to lock the length. As previously described, this method only allows for gross adjustment with constant user input and thus accurate size and fit are sacrificed to the detriment of the patient.
[0007] Another existing adjustment method utilizes a cam lever and a friction lock to adjust the length of the struts. When the cam lever is unlocked the support members freely move along the struts. This system allows for a range of adjustments and sizing. However, there is no way to index the components into position and as such, accurate adjusting, or re-adjusting, of the length of the portion of the brace is difficult to accomplish.
[0008] One aspect of the present invention is an adjustable orthopedic strut system that combines a locking system with an incremental or “micro” adjustment method that is size adaptable and easy to use. One embodiment of the present invention comprises a locking system, adjustable support members, struts, and an indented molded track. The present invention improves user fitting and sizing creating better support and comfort. The present invention provides “micro” incremental adjustments on support members to allow strategic positioning of the support members near surgical incisions without the need for constant user input. Furthermore, the present invention locks and telescopes on a non-interrupted strut surface with. minimal “snag” points thus reducing the difficulty in achieving fine adjustments. The system of the present invention easily indicates and indexes in a molded track and can be reduced in scale to fit many orthopedic devices to provide accurate micro-adjustments to a variety of applications and patients.
SUMMARY OF THE INVENTION
[0009] The present invention is a system comprising an orthotic brace with at least one hinge; a plurality of deformable struts comprising an indexable, micro-adjustable track, wherein the struts have a first end and a second end, and the first end of the strut is attached to the hinge; a plurality of innermost support members slidably attached to the struts wherein each innermost support member comprises a button, wherein the button is configured to engage the track, such that the support members may be incrementally indexed along the strut and locked when the support member is in the desired position along the track; and a plurality of outermost support members slidably attached to the second end of the struts wherein each outermost support member comprises a button, wherein the button is configured to engage the track, such that the support members may be incrementally indexed along the strut and locked when the support member is in the desired position along the track, thereby locking the outermost support member in position along the track and extend the apparent length of the strut.
[0010] In one embodiment of the present invention, the micro-adjustable track comprises a plurality of grooves wherein the plurality of grooves represent increments of adjustment. The increments may be the same along the length of the micro-adjustable track or vary along the length of the micro-adjustable track.
[0011] In one embodiment of the present invention, the increments are less than ⅓ of an inch apart. In another embodiment, the increments range from one quarter of an inch increments to one eighth of an inch increments on the same track.
[0012] In one embodiment of the present invention, the indexable, micro-adjustable track is flexible. In another embodiment, the indexable, micro-adjustable track is integral to the strut.
[0013] In one embodiment of the present invention, the struts are configured to be bent to properly fit a patient.
[0014] These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The foregoing and other objects, features, and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0016] FIG. 1A shows a side view of an entire orthotic knee brace with micro-adjustable telescoping arms of one embodiment of the present invention.
[0017] FIG. 1B shows a side view of an orthotic knee brace with micro-adjustable telescoping arms of one embodiment of the present invention.
[0018] FIG. 2 shows an enlarged view of the micro-adjustable telescoping arm of one embodiment of the present invention.
[0019] FIG. 3 shows a cross sectional view of the micro-adjustable telescoping arm of one embodiment of the present invention.
[0020] FIG. 4 shows a series of images ( 4 . 1 - 4 . 6 ) deconstructing the micro-adjustable telescoping arm of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] In one embodiment of the present invention, the orthotic brace is a knee brace. In certain embodiments, the orthotic knee brace comprises a “micro-adjustable” telescoping system comprising two bendable, lightweight struts or arms extending off an adjustable hinge located axially near the knee. In certain embodiments, one strut extends and telescopes up along the thigh and the other strut extends down the leg along the calf In one embodiment of the present invention, a series of tubular “telescoping” support members are located along these struts. These support members, when unlocked, are adjustable incrementally along a molded track. In certain embodiments, each of the support members has a strap running radially through it and adjustably connects around the body. The telescoping support members allow the brace to be fit to a variety of patients in specific locations along the leg.
[0022] In the current invention the strut or arms are connected to a rotatable hinge mechanism. This hinge mechanism is adjustable in both directions of flexion and extension, allowing the user incrementally to control the user's range of motion. However, it is not outside of the scope of this invention to use other hinge variations. Even attaching the upper and lower struts together in a simple rotatable fashion could suffice in certain applications. In relationship to the struts, the telescoping support members are connected to contoured paddles and allow the brace to be affixed to the user's body. The support member and paddle travel together along the bendable struts and are adjustable along, the length of the limb. These support members are mechanically locked in place once they have been fitted and adjusted to the correct orientation. The current invention's locking mechanism uses a slidable bezel and button configuration. This is not a permanent locking mechanism because support members may have to be readjusted based on the patient's healing patterns (and/or therapy). Once in place they are affixed to the user's body and secured with adjustable straps and closures.
[0023] Referring to FIG. 1A , one embodiment of a brace of the present invention is shown. More specifically, an orthotic knee brace of the present invention comprises a brace 100 with innermost 80 and outermost 60 telescoping support members located on a strut 70 . The innermost 80 and outermost 60 telescoping support members have padded straps 10 that reversibly connect the brace to the patient. In one embodiment of the present invention, the strut 70 has a molded micro-adjustable track 40 embedded in the strut 70 . The flexible, indexable micro-adjustable track is configured to remain integral to the strut when the strut is bent to fit a user so that the adjustment mechanism functions smoothly. An adjustable, locking hinge 20 separates the upper and lower portions of the orthotic knee brace of one embodiment of the preset invention. Easy to use, locking buttons 30 engage the track and hold the support members in place. The outermost support members 60 move along the strut, but also effectively lengthen the brace 100 . The innermost support members 80 allow for greater accuracy and flexibly in fitting the brace 100 to a particular patient. The buttons 30 are configured to be unlocked and have the support members slidably indexed along the length of the strut. Once the desired length has been achieved, the button can be locked into position.
[0024] Referring to FIG. 1B , a side view of one embodiment of an orthotic knee brace of the present invention with micro-adjustable telescoping arms is shown. More specifically, a brace 100 is shown with four moveable support members. The inner most support members 80 travel along a track 40 in the strut 70 . An indexed portion 50 provides for accurately reproducible adjustments for the support members. The outermost support members 60 also travel along a track 40 in the strut 70 . An indexed portion 50 provides for accurately reproducible adjustments for the support members. The support members contain paddles 90 that support and direct flexible, adjustable straps (not shown) which reversibly attach the brace to a patient. The hinge provides an adjustable, locking mechanism to control the range of motion for both flexion and extension. Locking buttons 30 are located on the tubular support members and engage the track to provide easy to use, micro-adjustability for each support member. Each support member has the ability to be readjusted repetitively to fit the brace to the patient as needed.
[0025] Referring to FIG. 2 , an enlarged view of the micro-adjustable telescoping arm of one embodiment of the present invention is shown. More specifically, FIG. 2 shows one embodiment of the telescoping support member 80 , which rides over and along the strut 70 . The support member indexes the micro-adjustment using the gradations along the arm 50 . The support member comprises an easy to use, easy to lock/unlock button 30 , which engages the micro-adjustable track 40 . Semi-flexible paddles 90 are carried on the support members and position and hold flexible straps (not shown), which reversibly attach the brace to a patient.
[0026] Referring to FIG. 3 , a cross sectional view of the micro-adjustable telescoping arm of one embodiment of the present invention is shown. More specifically, FIG. 3 shows one embodiment of the locking button 30 of the present invention. In certain embodiments, the locking button is recessed into a bezel and comprises a locking tooth for engaging the track 40 . In another variation, it is possible for the locking feature to be part of the telescope and the locking button can vary in motion, such as a rotation or lever instead of a slide. Conversely, a containing pin can be used instead of a locking arm and pressed down into the track by a slide, rotation or lever.
[0027] As seen in FIG. 4 , one embodiment of the present invention is an orthotic brace with a cut out in the elongated support that incorporates a modular approach to building the brace. This modular approach offers a series of benefits including 1) the molded track can be embedded inside the metal support to create an internal low profile design, 2) the molded track bends more easily with the support than if it were mounted or applied, 3) the molded track can be specifically designed to have the proper locking geometry, 4) the molded track can be changed and incorporated into an existing metal stamping, 5) the separate molded track allows for significant control in material choice, and 6) the separate molded track provides the advantage of being able to change materials without interrupting the design.
[0028] Referring to FIG. 4 , a series of images ( 4 . 1 - 4 . 6 ) deconstructing the micro-adjustable telescoping arm of one embodiment of the present invention is shown. More specifically, in FIG. 4.1 the full assembly of the slidable and lockable plastic button is shown. Plastic material options for all of the following related components include ABS, polypropylene, polyethylene, nylon, polycarbonate and even compounded resins. In FIG. 4.2 , the mechanical, snap-fit slidable button is removed to expose the fixed bezel portion with an integrated locking button, which comprises a locking tooth to engage the track. In this assembly, the bezel is snap-fit into position. However, in other configurations it can easily be adhesively bonded or mechanically fastened. In FIG. 4.3 , the bezel is removed to expose the portion of the support member, which surrounds the strut. Its tubular design allows it to travel closely along the strut. In FIG. 4.4 , the tube portion of the support member is removed to expose the track in the arm. The tubular support member may be mechanically joined to the paddle by means of adhesive, fasteners, snap-fit, sonic welding or even the heat stake process. In FIG. 4.5 , the adjustment track is removed to expose the paddle 90 as is interacts with the arm. in FIG. 4.6 , the paddle is finally removed to expose the arm.
[0029] In one embodiment of the present invention, the struts for the orthotic brace utilize laser or die cut metal. In certain embodiments, the struts utilize 6061 T6 aluminum. This material choice is strong, lightweight, non-corrosive and bendable. However, other sufficient strut material replacements include aluminum alloys 7075 and 5052 for their specific metallurgical properties.
[0030] In one embodiment, the adjustable track is molded from an ABS blend and slides into place through a series of snaps and slides. Considering there are many choices of plastics with this approach the material can be reconfigured to create a different result. The product can be made more flexible or rigid depending on the plastics blend and composition. Other viable materials for the track include polypropylene, nylon, polyester, polycarbonate and even compounded resins. Furthermore, since the part is molded, the track can be configured to a variety of shapes and geometries. Results from this include a range of different increments of adjustment.
[0031] For example, in certain embodiments, the track is molded to be more adjustable in a specific area allowing the engagement tooth from the locking mechanism to change from eighth of an inch increments to one quarter of an inch increments on the same track. This creates the advantage of fully controlling the micro adjustment of the brace if desired. The flexibility of the micro-adjustable telescoping arms of the present invention allow for orthoses that are easy to adjust and to re-adjust as needed by each particular patient at each particular stage of treatment. The fine adjustments provide a more accurate and secure lit for a large variety of patients who are dealing with a range of different injuries and/or surgeries.
[0032] In one embodiment, the adjustable track is adjustable in a range of ⅛ ″ increments. However other possible increments include 3/16″ and ¼″ if desired and Metric equivalents.
[0033] Within the scope of a modular design in one embodiment of the present invention, the ability separately to mold the adjustable track allows for many functional advantages. One benefit of the modular design of one embodiment of the present invention includes having incremental control of the support members around a patient's surgical site or sites. Another benefit of one embodiment of the present invention is the ability to change the increment engagement along the track if fine increments are not needed. Another benefit of one embodiment of the present invention is having certain smooth areas along the track and/or non-locking areas along the track for certain applications.
[0034] One embodiment of the brace of the present invention attaches to the patient's leg through a series of straps woven through the support members. To make the brace adjustable (telescoping) the support members must travel up and down the strut assembly. It is, however, essential that the support members move easily along the strut assembly and still maintain the ability to be locked into position. This is in contrast to other patents like U.S. Pat. No. 7,385,406 and U.S. Pat. No. 6,821,261 that require downward pressure to be constantly applied to the button in order to extend the length of the brace. This makes adjustment, albeit coarse adjustment, tedious and awkward as you travel from one point to the next. It is desirable to have fine adjustments, but also to have smooth adjustments when dealing with an injured patient.
[0035] In certain embodiments of the present invention, the support member and locking mechanism are made up of the following: a support member molded as a tubular channel (Lustran or other ABS equivalent) that excepts the bezel and button mechanism; a molded bezel (Lustran or other ABS equivalent) with integrated locking tooth that snaps into the support member; a molded button (Lustran or other ABS equivalent) that snap tits into the bezel located in the support member. The bezel and button assembly is permanently mounted into the support member through a series of interference fits. In certain embodiments, the completed assembly has the ability to be repeatedly locked/unlocked into position. As the brace is being fit in the unlocked position, the locking tooth floats along the incremental track in and out of molded valleys. This allows the person applying the brace not to have to keep his finger on the button until it is ready for final engagement. Once the brace is fully adjusted the support members are then locked into position. If any more “micro-adjustment” is desired, the person simply unlocks the button and continues to fit the brace. This helps in fitting around surgical sites and tender areas by repositioning the supports delicately and with fine degrees of adjustment.
[0036] The micro-adjustment system of the present invention is very distinct from prior art in a number of ways. First, U.S. Pat. No. 7,383,406 and U.S. Pat. No. 6,821,261 telescope by indexing a tensioned button into stamped metal holes. As the holes get too small and incremental, the button/lock becomes more difficult to locate into position. Because of this, the holders of these patents have manufactured their product with one half inch increments. Second, U.S. Pat. No. 3,805,773 uses punched holes in metal and a releasable pin to index the telescoping struts providing only similarly gross adjustments. The micro-adjustable telescoping arms of the present invention offer a novel solution to both problems by having a track with incremental “micro-adjustment” spacing and a hands five corresponding lock/unlock button. These embodiments present the benefits of telescoping “micro-adjusting” support members with an easy to use luck/unlock button.
[0037] In another embodiment of the present invention, the orthotic brace may be integrally molded, machined or stamped such that the track and strut is one unit. In certain embodiments, braces can incorporate a single material strut. In certain embodiments, the single material strut can be a knee brace. in certain embodiments, the single material strut can he an elbow brace or T.L.S.O. back brace component. Additionally, the strut can be applied to a brace where the strut is used as a “stay” and does not require a bend. In certain embodiments of the present invention, the strut is comprised of lightweight composites, molded plastics, extruded plastics, and the like.
[0038] While the principles of the invention have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the invention. Other embodiments are contemplated within the scope of the present invention in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention.
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The adjustable orthopedic strut system comprises a locking system with an incremental or “micro” adjustment method that is size adaptable and easy to use. The adjustable orthopedic strut system comprises a locking system, adjustable support members, struts, and an indented molded track. The adjustable orthopedic strut system improves user fitting and sizing creating better support and comfort. The adjustable orthopedic strut system provides “micro” incremental adjustments on support members to allow strategic positioning of the support members near surgical incisions. Furthermore, the adjustable orthopedic strut system locks and telescopes on a non-interrupted strut surface with minimal “snag” points, thus reducing the difficulty in achieving fine adjustments. The system of the present invention easily indicates and indexes in a molded track and can be reduced in scale to fit many orthopedic devices to provide accurate micro-adjustments to a variety of applications and patients.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a phase difference detection circuit, a phase difference detecting method, an optical disk drive, and an optical disk drive controlling method.
2. Description of Related Art
Nowadays, optical disks such as CD (compact disc) and DVD (digital versatile disc) have been widely available. In addition, new optical disks have been under development. Optical disk drives that read/write information from/to the optical disk amplify and shape signals read through light pick-up to supply read data to a PLL (phase locked loop) circuit. The PLL circuit generates a read clock synchronized with the read data. The read data is extracted in accordance with the synchronized read clock and subjected to signal processing to obtain final reproduction data.
At this time, attention should be paid to the fact that data read from the disk involves fluctuation in the time axis direction called “jitter”. The jitter is caused by a reading device inclined with respect to a reading surface of the disk, that is, the optical axis of a reproducing laser beam not vertical to the disk surface, or the laser power inadequate for writing data. In some cases, correct signals cannot be input, leading to an error in reading data or correct data cannot be obtained due to the jitter.
Further, a read clock that is generated based on the read data with the jitter involves the jitter. In this case, an important problem is not the jitter in both the read data and the read clock but a relative phase difference. In such a case, even if the jitter of the read data is only detected without considering the jitter of the read clock, the detected jitter is different from a relative phase difference as a practical problem.
To that end, a method of detecting a jitter has been under study, and there have been some proposals. As the method of detecting the jitter, there has been proposed a method of inputting a read clock signal the rising/falling edge of which appears concurrently with that of the read data signal and detecting a delay therebetween with a counter (see Japanese Unexamined Patent Publication No. 2001-273715 (Kobayashi), for instance).
The related art disclosed in Kobayashi is discussed in brief. FIG. 10 shows the structure of a jitter detecting device of the related art. The jitter detecting device of the related art generates a read clock of which the edge is synchronous with that of the input read data by means of a PLL circuit 30 , and a phase difference between the read data and the read clock is detected with a phase difference detection circuit 32 .
The phase differential signal detected by the phase difference detection circuit 32 is output to a Schmitt circuit 33 . The Schmitt circuit 33 compares the received phase difference with a threshold value preset by a threshold setting register 31 , and sends, if the received phase difference exceeds the threshold value, this comparison result to a counter 34 . The counter 34 increments a count value by 1 when the phase difference exceeds the threshold value.
The count value of the counter 34 is recorded in a register 35 . The recorded value is output to a CPU through a CPU interface as needed. It is thus possible to count the number of times the phase difference exceeds the present threshold value.
With this method, however, the circuit is operated with reference to the edge of the read data signal, a delay of the read clock signal can be detected but the jitter of the advanced read clock signal cannot be detected. Further, the method only counts the number of times the threshold value is exceeded, thus it is impossible to evaluate the phase difference deviation of the rising edge and falling edge of the read data signal. It is still another problem that the jitter cannot be detected in consideration of the jitter of the read clock signal itself.
As mentioned above, the jitter detecting method using the conventional phase difference detection circuit is incapable of detecting the jitter of the advanced read clock signal. As another problem thereof, the jitter cannot be relatively detected in consideration of the influence of the jitter in the read clock signal itself.
SUMMARY OF THE INVENTION
An aspect of the present invention provides a phase difference detection circuit for detecting a phase difference between input data and an input clock generated based on the input data. An input data edge position detector detects an edge position of the input data based on an N-phase clock (N is an integer of 2 or more). An input clock edge position detector detects an edge position of the input clock based on the input clock and the N-phase clock. A phase difference detector detects the phase difference between the input data and the input clock based on the edge position of the input data and the edge position of the input clock. According to this circuit configuration, edge positions of both of input data and an input clock are detected, making it possible to obtain jitters of both of the input data and the input clock to calculate a relative jitter.
Another aspect of the present invention provides a phase difference detecting method for detecting a phase difference between input data and an input clock generated based on the input data. An edge position of the input data is detected based on an N-phase clock. An edge position of the input clock is detected based on the input clock and the N-phase clock. The phase difference between the input data and the input clock is detected based on the detected edge position of the input data and the detected edge position of the input clock. According to this method, edge positions of both of input data and an input clock are detected, making it possible to obtain jitters of both of the input data and the input clock to calculate a relative jitter.
According to the present invention, it is possible to provide a phase difference detection circuit capable of detecting edge positions of both input data and input clock to detect a jitter of the input data relative to a jitter of the input clock.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, advantages and features of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram showing the configuration of a phase difference detection circuit according to the present invention;
FIG. 2 is a block diagram showing the configuration of a data rising edge detection circuit according to the present invention;
FIG. 3 is a timing chart showing rising/falling timings of read data and clock signals of read clock and N-phase clock according to the present invention;
FIG. 4 shows a relationship between edge values input to an edge position encoding circuit and output encoded-data according to the present invention;
FIG. 5 shows a relationship between a subtraction result and generated difference data according to the present invention;
FIG. 6 is a block diagram showing the configuration of a subtracter according to the present invention;
FIG. 7 is a timing chart showing a processing flow for a read data signal, a read clock signal, N-phase clock signal, detected edge positions, and output phase differences according to the present invention;
FIG. 8 is a graph showing a relationship between the inclination of an optical disk and a phase difference of a read data signal according to the present invention;
FIG. 9 is a block diagram showing the configuration of an optical disk device according to the present invention; and
FIG. 10 shows the configuration of a jitter detecting device of the related art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention will be now described herein with reference to illustrative embodiments. Those skilled in the art will recognize that many alternative embodiments can be accomplished using the teachings of the present invention and that the invention is not limited to the embodiments illustrated for explanatory purposed.
First Embodiment of the Invention
FIG. 1 shows the overall configuration of a phase difference detection circuit according to the present embodiment. A phase difference detection circuit 1 includes a PLL circuit 10 , a data rising edge detection circuit 11 , a data falling edge detection circuit 12 , a clock falling edge detection circuit 13 , edge position encoding circuits 14 , 15 , and 16 , subtracters 17 , 18 , and a memory 19 .
The PLL circuit 10 receives a read data signal to generate a read clock signal synchronous with the rising/falling edge of the received read data signal. The generated read clock signal is output to a clock falling edge detection circuit 13 .
The data rising edge detection circuit 11 receives the read data signal and an N-phase clock signal to detect a rising edge position of the received read data signal with reference to the received N-phase clock signal. The N-phase clock signal consist of N types of signals having the same cycle as the read clock signal and the phases of which are shifted from one another by 360°/N. Here, N is an integer of 2 or more, preferably, 2 to the Mth power (M is an integer of 1 or more) such as 2, 4, 8, and 16. In the embodiment of the present invention, N=8. The method of detecting the edge based on the N-phase clock signal is detailed later. Information about the detected edge position is sent to the edge position encoding circuit 14 .
The data falling edge detection circuit 12 receives the read data signal and the N-phase clock signal to detect a falling edge position of the received read data signal based on the received N-phase clock signal. Information about the detected edge position is output to the edge position encoding circuit 15 .
The clock falling edge detection circuit 13 receives the read clock signal and the N-phase clock signal to detect the falling edge position of the received read clock signal based on the received N-phase clock signal. The read clock signal is generated by the PLL circuit 10 . Information about the detected edge position is sent to the edge position encoding circuit 16 .
The edge position encoding circuits 14 , 15 , and 16 encode the received information about the edge positions. An encoding method is described in detail later. The encoded data are output to the subtracters 17 and 18 .
The subtracter 17 generates difference data of the edge position encoded data supplied from the edge position encoding circuits 14 and 16 , and the subtracter 18 generates difference data of the edge position encoded data supplied from the edge position encoding circuits 15 and 16 . The generated difference data are sent to the memory 19 .
The memory 19 stores the difference data supplied from the subtracters 17 and 18 . The stored difference data are output in response to a request from a CPU or other such units.
Subsequently, a method of detecting a rising edge position of the read data signal with the data rising edge detection circuit 11 is described. FIG. 2 shows the configuration of the data rising edge detection circuit 11 according to the present invention. The data rising edge detection circuit 11 includes variation point detection circuits 110 to 117 , and an arithmetic logical circuit 118 .
Specifically, for example, the variation point detection circuit 110 receives a signal CLK 0 of the N-phase clock signal, and determines whether or not the rising edge of the separately received read data signal falls within an area of the CLK 0 . If the determination result is positive, “1” is sent to the arithmetic logical circuit 118 as DATA 0 ; otherwise, “0” is sent. The same applies to the remaining variation point detection circuits 111 to 117 except for the received signals of the N-phase clock signal.
The arithmetic logical circuit 118 executes arithmetic operation based on the respective data from the variation point detection circuits 110 to 117 to output the arithmetic operation result as EDGE 0 to EDGE 7 . The arithmetic operation as illustrated in the arithmetic logical circuit 118 of FIG. 2 is executed. For example, EDGE 0 is 1 when DATA 0 is 1, and DATA 7 and DATA 1 are 0; otherwise, EDGE 0 is 0. Similarly, each EDGE takes 1 only when corresponding DATA is 1, and adjacent DATA values are 0; otherwise, EDGE takes 0.
As describe above, the variation point detection circuits 110 to 117 each detects a logical level of the input data at each clock edge of the N-phase clock. The arithmetic logical circuit 118 determines the kth (k is an integer) clock of the N-phase clock as an edge timing of the input data if the kth variation point detection circuit detects HIGH and the (k−1)th and the (k+1)th detection circuits detect LOW.
Detailed description thereof is given taking a specific example. FIG. 3 is a timing chart showing timings of rising/falling edges of read data and signals of the N-phase clock signal. In the illustrated example of FIG. 3 , the first rising edge of the read data appears between the rising edges of CLK 2 and CLK 3 of the N-phase clock. In this case, DATA 3 and subsequent DATA's show pulse rises in sync with the rising edges of CLK 3 and subsequent CLK's, and the values thereof are output from the variation point detection circuits 110 to 117 to the arithmetic logical circuit 118 . Then, as a result of the logical operation of the arithmetic logical circuit 118 , EDGE 3 takes 1, and the remaining EDGE's take 0. Likewise, on the second rising edge, EDGE 6 takes 1, and the remaining EDGE's take 0.
In this way, the data rising edge detection circuit 11 can determine an area where the rising edge of the target read data signal appears from among the areas divided according to the N-phase clock signal, and output the determination result as bit data.
The data falling edge detection circuit 12 and the clock falling edge detection circuit 13 have the same circuit configuration as the data rising edge detection circuit 11 except that the detecting position for the variation point is changed to the falling edge of the read data and the falling edge of the read clock data.
The edge positions detected with the data rising edge detection circuit 11 , the data falling edge detection circuit 12 , and the clock falling edge detection circuit 13 are sent as the bit data to the edge position encoding circuits 14 , 15 , and 16 , respectively. The edge position encoding circuits 14 , 15 , and 16 encode the received bit data about the edge position.
FIG. 4 shows a relationship between the values of the EDGE 0 to EDGE 7 input to the edge position encoding circuits 14 , 15 , and 16 and the output encoded-data. The EDGE 0 to EDGE 7 can be encoded into 3-bit data since one of them is 1 and the rest are 0, which means 8 patterns in total.
The encoded data generated with the edge position encoding circuits 14 , 15 , and 16 are supplied to the subtracters 17 and 18 , and the subtracters 17 and 18 generate difference data. The subtracter 17 generates difference data representative of a difference between rising edge position encoded data of the read data signal from the edge position encoding circuit 14 and falling edge position encoded data of the read clock signal from the edge position encoding circuit 16 . The subtracter 18 generates difference data representative of a difference between falling edge position encoded data of the read data signal from the edge position encoding circuit 15 and falling edge position encoded data of the read clock signal from the edge position encoding circuit 16 . As a result thereof, the relative difference data between the read data signal and the read clock signal can be obtained. Further, it is possible to deal with the case where the N-phase clock involves the jitter. For example, if the N-phase clock has the jitter of Δ, the calculation is such that (read data edge+Δ)−(read clock edge +Δ)=(read data edge)−(read clock edge), so the jitter of the N-phase clock can be cancelled out.
FIG. 5 shows the relationship between the subtraction result and the generated difference data. When N=8, the maximum absolute value of the phase difference is 4. Thus, if the calculation result is 5, the absolute value of the phase difference is 3. If the subtraction result is 6, the absolute value of the phase difference is 2. If the subtraction result is 7, the absolute value of the phase difference is 1.
If N is 2 to the Mth power (M is an integer of 1 or more) such as 8 or 16, the subtracters 17 and 18 can be configured as shown in FIG. 6 . The subtracter 17 includes a subtracter circuit 170 , an all-bit inverter circuit 171 , a +1 adder circuit 172 , and a selector 173 .
The subtracter circuit 170 executes the subtraction processing on the received two encoded data about the edge position to send the subtraction result to the all-bit inverter circuit 171 and the selector 173 . The all-bit inverter circuit 171 executes the bit-inversion on the received encoded data to output the bit-inverted data to the +1 adder circuit 172 . The +1 adder circuit 172 adds 1 to the data supplied from the all-bit inverter circuit 171 to send the addition result to the selector 173 . In the case of N=8, the selector 173 selects, if the subtraction result from the subtracter circuit 170 is 4 or less, the subtraction result received from the subtracter circuit 170 , and selects, if the result is more than 4, the addition result received from the +1 adder circuit 172 to send the selected one to the memory 19 . Provided that N=16, the selector 173 selects a desired one depending on whether or not the subtraction result is 8 or less.
Owing to such a circuit configuration, the subtracters 17 and 18 can send the phase difference calculated on the basis of the subtraction result of FIG. 5 to the memory 19 .
The memory 19 stores the phase difference data received from the subtracters 17 and 18 as 3-bit data (if N=8). The stored phase difference data are read in response to a request from a CPU or other such units on the other end. There is no particular limitation on the application of the stored phase difference data.
FIG. 7 is a timing chart showing a processing flow for a read data signal, a read clock signal, N-phase clock signal, detected edge positions, and output phase differences. On the first rising edge edgeT 1 of the read data, the rising edge position is “3”, and the corresponding falling edge position of the read clock is “5”, so the phase difference equals “2”. Likewise, on the first falling edgeT 2 of the read data, the falling edge position is “2”, and the corresponding falling edge position, which is different from the above corresponding falling edge position, of the read clock is “5”, so the phase difference is “3”.
On the second rising edgeT 3 of the read data, the rising edge position is “0”, and the corresponding falling edge position of the read clock is “6”, so the difference equals −6, but the actual phase difference becomes “2” with the use of the subtracter 17 . On the second falling edgeT 4 of the read data, the falling edge position is “6”, and the corresponding falling edge position of the read clock is “6”, so the phase difference equals “0”.
According to this configuration, the rising edge and the falling edge of the read data can be determined with respect to the falling edge of the read clock, so the phase difference reflecting the jitter of the read clock can be obtained. In addition, the phase difference is calculated separately on the rising edge and the falling edge, so more accurate phase difference data can be offered.
Second Embodiment of the Invention
A description is given of an example in which the phase difference detection circuit of the present invention is applied to an optical disk device. The optical disk device is known to largely vary a phase difference of a read data signal upon, for example, data reproduction due to the inclination of a reading device with respect to a reading surface of the disk. FIG. 8 shows the relationship between the inclination of the reading device with respect to the reading surface of the disk, and the phase difference of the read data signal. To minimize the error resulting from the phase difference, it is necessary to find a point of the graph of FIG. 8 , at which the phase difference is minimized. The phase difference detection circuit of the present invention is applicable to the optical disk device for that purpose.
FIG. 9 is a schematic diagram focused on the structure related to the phase difference detection circuit of the present invention in the optical disk device of the present invention. The optical disk device 2 includes a CPU 20 , a CPU interface 201 , a memory 21 , a memory interface 211 , a phase difference detection circuit 22 , a PLL circuit 23 , an N-phase clock generator circuit 231 , a data comparator 24 , a motor driver 25 , a laser driver 251 , an RF amplifier 26 , a pick-up 27 , a spindle motor 28 , and a digital servo processor 29 .
The CPU 20 executes various types of control over the optical disk device 2 . The CPU interface 201 controls the data exchange between the CPU 20 and the memory interface 211 , the phase difference detection circuit 22 , the PLL circuit 23 , or the data comparator 24 .
Programs for controlling the optical disk device 2 or various types of data are recorded/read on/from the memory 21 . The memory interface 211 controls the data exchange among the memory 21 , the CPU 20 , and the phase difference detection circuit 22 .
The phase difference detection circuit 22 detects the phase difference between the received read data signal and read data clock. The phase difference detection circuit has the same configuration as that of the first embodiment of the present invention as shown in FIG. 1 , but the PLL circuit 10 of FIG. 1 may be replaced by the PLL circuit 23 , and the memory 19 may be replaced by the memory 21 , both of which may be omitted from the phase difference detection circuit 22 of the present invention. The phase difference detecting method is the same as the first embodiment of the present invention.
The PLL circuit 23 generates and outputs read clock signals based on the read data signal received from the data comparator 24 to the phase difference detection circuit 22 and the N-phase clock generator circuit 231 .
The N-phase clock generator circuit 231 receives the read clock signal from the PLL circuit 23 to generate N-phase clock based on the received read clock signal. The N-phase clock generator circuit 231 sends the generated N-phase clock to the phase difference detection circuit 22 .
The data comparator 24 slices the RF signals received from the RF amplifier 26 at a given slice level into binary data. This binary data is the read data signal. The generated read data signal is sent to the phase difference detection circuit 22 and the PLL circuit 23 .
The motor driver 25 controls the rpm of the spindle motor 28 based on rotational servo signals supplied from the digital servo processor 29 . Besides, the motor driver 25 controls the pick-up 27 based on a tracking servo signal and focus servo signal received from the digital servo processor 29 .
The laser driver 251 controls the pick-up 27 based on the correction amount from the CPU 20 to adjust the laser power.
The RF amplifier 26 amplifies and applies the beam shaping to the signals received from the pick-up 27 to generate and send RF signals to the data comparator 24 .
The pick-up 27 reads the data from the optical disk under the control of the motor driver 25 to send the read signal to the RF amplifier 26 . The spindle motor 28 rotates the optical disk under the control of the motor driver 25 .
The digital servo processor 29 generates and sends rotational servo signals, tracking servo signals, and focus servo signals to the motor driver 25 under the control of the CPU.
Subsequently, the application of the phase difference detected by the phase difference detection circuit 22 is described. The phase difference data supplied from the phase difference detection circuit 22 is stored in the memory 21 . The phase difference data stored in the memory 21 is sent to the CPU 20 , and the CPU 20 executes various types of control based on the phase difference data.
Examples of the control include, in addition to the foregoing adjustment of the inclination of the reading device with respect to the disk's reading surface, control of the laser power for writing the data to the optical disk. The data is written to the optical disk through turn on/off of the laser, so the laser power significantly influences the recording quality. Unless the optimum laser power is used, the obtained data of the read data signal is distorted, so the offset occurs on the edge. How far the data is distorted varies depending on the quality of the optical disk, so it is necessary to adjust the laser power so as to deal with various recording mediums. For that purpose, the phase difference detection circuit 22 detecting the deviation on the edge can be used.
The laser power is adjusted such that the CPU 20 sends the correction amount data to the laser driver 251 based on the received phase difference data. Receiving the correction amount data from the CPU 20 , the laser driver 251 adjusts the laser power based on the correction amount data.
The phase difference data can be used for adjusting the RF signals. In this case, the CPU 20 adjusts the settings of a DC level of the RF amplifier 26 , gain, or an output current of a driver.
Similarly, the correction amount data based on the phase difference is converted into analog data, enabling various types of control. In this case, the correction amount is sent to the digital servo processor 29 based on the phase difference data received from the CPU 20 . The digital servo processor 29 converts the received correction amount data into analog data to be sent to the motor driver 25 . The motor driver 25 controls the spindle motor 28 based on the received correction amount. Further, the motor driver 25 controls the pick-up 27 based on the received correction amount. In this way, the pick-up 27 and the spindle motor 28 are controlled, making it possible to control tracking or focusing processings or adjust the reading device with respect to the disk's reading surface based on the detected phase difference.
Other Embodiment of the Invention
In the above example, the phase difference data is recorded as the absolute value of 0 to 4 but may be recorded as a signed relative phase difference.
Further, in the above example, the N-phase clock is generated based on the input read clock data but maybe generated based on other clock generated inside an LSI or may be externally applied. In addition, the N-phase clock signal has N types of signals whose phases are shifted from one another by 360°/N. However, the degree of phase shift is not particularly limited insofar as it is determined which of N divided areas the edge appears in.
In addition, in the above example, the phase difference is calculated based on the falling edge of the read clock signal, the rising and falling edges of the read data signal but may be calculated based on the rising edge of the read clock signal, and the rising and falling edges of the read data signal.
It is apparent that the present invention is not limited to the above embodiment and it may be modified and changed without departing from the scope and spirit of the invention.
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An embodiment of the present invention provides a phase difference detection circuit for detecting a phase difference between input data and an input clock generated based on the input data, including: an input data edge position detecting part detecting an edge position of the input data based on an N-phase clock obtained by dividing a predetermined period into N areas (N is an integer of 2 or more); an input clock edge position detecting part detecting an edge position of the input clock based on the input clock and the N-phase clock; and a phase difference detecting part detecting the phase difference between the input data and the input clock based on the edge position of the input data and an edge position of the input clock.
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BACKGROUND
1. Field
The present disclosure relates to a process and associated methods to harden a hardfacing weld overlay alloy. More specifically, the present disclosure relates to a heat-treatment process to harden the weld overly of an iron-chromium-carbide hardfacing alloy to significantly improve the resistance of the weld overlay against erosion, abrasion, and erosion-corrosion.
2. General Background
Fe—Cr—C alloy system is a well known hardfacing material. Carbon is needed to form hard particles of carbide to contribute the alloy's resistance to erosion or abrasive wear. More carbon in the alloy forms more volume fraction of carbides, thus exhibiting more resistance to wear. Thus, common hardfacing alloys of this type contain more than 2% carbon. Chromium is added to the alloy to form much more stable chromium carbides instead of less stable iron carbides (if no chromium in the alloy). Chromium is also useful in increasing the alloy's oxidation resistance by forming chromium oxides when the component is intended for services at high temperatures. This group of hardfacing alloys is often referred to as “high-alloy white cast irons”. General discussion of this group of hardfacing alloys can be found in ASM Handbook, Vol. 4, Heat Treating, p. 700. The alloys are typically used in forms of castings or hardfacing weld overlays. The large volume of eutectic carbides in the microstructure of a casting or weld overlay provides high hardness for abrasion resistance.
Alloys of various compositions in this group are also subject to heat treatments to produce additional hardening by forming martensite in the alloy. This martensitic phase transformation is a well known phase transformation in Fe—C alloy system by heating the alloy at a high temperature in an austenitic phase range followed by fast cooling to a temperature below the critical temperature, typically referred to as M s temperature (i.e., the temperature when the martensite phase starts forming at the temperature when the metal is being cooled to room temperature. The hardness of the alloy will significantly be increased when the microstructure of the alloy contains martensite. The M s temperature varies depending on the composition of the alloy. Some high chromium alloys exhibit such very low M s temperatures that the alloys have to be cooled well below room temperature in order to produce additional hardening by forming martensite. These alloys are to be refrigerated in order to transform the austenite phase to martensite phase for additional hardening. Typical of such alloys are those described in U.S. Pat. Nos. 3,941,589, 4,547,221, and 5,183,518. U.S. Pat. No. 3,941,589 describes alloy composition comprising 2.5-3.5% carbon, 2.5-3.5% manganese, 12-22% chromium, 1-2% silicon, 1.5-3.0% molybdenum, 1-2% copper, and balance iron. The alloy of this referenced invention is hardened by transformation of some austenite to martensite by a refrigeration heat-treatment involving cooling the metal to a temperature usually below about −100° F. (−75° C.) for a period of time. U.S. Pat. No. 4,547,221 describes alloy composition comprising about 2.6-3.6% carbon, about 12-22% chromium, about 0.5-1.1 manganese, about 1.0-3.0% molybdenum, about 0.5-1.5% copper, about 1.4-2.5% nickel, about 1.4-2.5% silicon, and balance iron. The alloy of this invention is also hardened by a refrigeration heat-treatment involving cooling the metal to a temperature usually below −100° F. (−75° C.) for a period to allow additional austenite to transform to martensite. U.S. Pat. No. 5,183,518 describes alloy composition comprising 2.4-3.8% carbon, 0.4-2.0% manganese, 0.2-1.9% silicon, 0.0-3.0% copper, 1.5-4.5% nickel, 12.0-29.0% chromium, and the remainder iron. The alloy of this invention is hardened by cooling the metal to a cryogenic temperature of about −55° C. (a temperature well below the M s temperature for the alloy) for a sufficient time to form martensite. Some Fe—Cr—C hardfacing alloys have a much higher M s temperature, which allows formation of martensite when cooled to room temperature. Typical of such alloys is described in U.S. Pat. No. 6,375,895. U.S. Pat. No. 6,375,895 describes alloy composition comprising about 0.65-1.1% carbon, about 4.5-10.5% chromium, about 0.05-1.0% molybdenum, and balance iron. This hardfacing alloy is suited for welding on the surfaces for protection from abrasion wear. The alloy weld metal can be hardened by forming martensite when cooled down to room temperature.
It is well known that the martensite phase forms when a high-temperature austenite phase in a face-centered cubic structure of steel is cooled to a temperature below M s temperature to form martensite having a body-centered tetragonal structure with all the carbon atoms being trapped in the structure that produces severe strain in the martensite. As a result, a significant hardening is produced in the metal when martensite is formed. The martensite is not thermally stable. This means when the metal is heated to above M s , which is the temperature martensite starts to form when the metal is being cooled to lower temperatures from an austenitizing temperature, the trapped carbon atoms in the martensite diffuse away from a highly distorted body-centered tetragonal structure that turns into a regular, non-distorted body-centered cubic structure, thus eliminating all the strain in the metal and losing the hardening. The M s temperature, depending on the alloy chemistry, can be very low for some alloys. For example, M s temperature of the alloy comprising 2.4-3.8% carbon, 0.4-2.0% manganese, 0.2-1.9% silicon, 0.0-3.0% copper, 1.5-4.5% nickel, 12.0-29.0% chromium, and the remainder iron is below 150° C. (U.S. Pat. No. 5,183,518). Accordingly, the metal that is hardened by martensite cannot maintain its abrasive wear resistance when exposed to elevated temperatures. Furthermore, the high hardness produced by martensite formation is the result of severe strain produced by a distorted crystal structure, not by hard particle phases. Hardness produced this way is not known to exhibit resistance to erosion by the particles-entrained flue gas streams generated in many industrial environments, such as boilers or petrochemical processing.
High alloy white cast irons, which typically contain more than 2% carbon along with chromium and other alloying elements as discussed earlier, contain a large volume of eutectic carbides that provide abrasive wear resistance. These alloys are normally used in castings for machinery in crushing, grinding and other applications for handling abrasive materials. When these alloys are used as a hardfacing, such as a weld overlay, on a metallic component to resist abrasive wear, the weld overlay can develop stress cracks due to large volume of eutectic carbides. In some industrial applications, these stress cracks in the weld overlay may not present performance or safety related issues. However, in some other applications involving pressure boundary components, such as boilers and vessels as well as piping, the weld overlay on these components is to be free of stress cracks. The alloys that are suitable for applications as a weld overlay for these critical components would require a composition containing lower carbon content with lower volume of eutectic carbides. This will allow the use of welding process to produce a hardfacing weld overlay without developing stress cracks. However, when the volume of eutectic carbides is reduced as a result of lowering carbon content, the alloy's wear resistance is also reduced because of lower hardness. It becomes important that a novel heat-treatment method be developed to further harden a crack-free weld overlay to significantly improve the overlay's resistance to abrasive, erosion wear.
HF35 is a hardfacing alloy comprising about 0.8-1.2% carbon, about 20-23% chromium, about 2.5-3.5% nickel, about 0.2-0.5% zirconium, about 0.5-1.0% molybdenum, about 1.0-2.0% manganese, about 1.0-2.0% silicon, and balance iron along with impurities and incidental elements. The alloy contains much lower carbon as compared with high-alloy white cast irons and other Fe—Cr—C eutectic carbide alloys. The level of chromium in the alloy is (a) to form more stable eutectic chromium carbides (instead of eutectic iron carbides if no or low chromium in the alloy) and (b) to form chromium oxide scales when used at high temperatures to improve oxidation resistance in order to improve the alloy's resistance to erosion/corrosion. Nickel of about 3% is to increase the stability of austenite and improve the alloy's toughness. Additions of other alloying elements, such as molybdenum and zirconium, are intended to further improve the alloy's abrasion, erosion, and erosion/corrosion resistance. Due to much lower carbon content, the volume of eutectic carbides is much reduced, thus resulting in lower hardness. When the alloy is weld overlaid on a component, such as tube, pipe, vessel, or boiler waterwall, the overlay does not develop cracks. However, the alloy's resistance to abrasion or erosion wear is compromised because of its lower hardness. The hardness for the weld overlay of this hardfacing is typically RC 35-40 in the as-overlaid condition.
A hardfacing alloy with hardness of about RC 35-40 is generally considered to be resistant to moderately abrasive and erosive environments. For highly abrasive and erosive conditions, such hardfacing alloy with hardness of about RC 35-40 is not likely to perform well. For example, HF35 overlay tubes were tested as part of the in-bed evaporator tube bundle in a fluidized-bed coal-fired boiler that generates electricity. The overlay tubes were tested for about three years. Two tubes were then removed for evaluation. The examination showed that the HF35 overlay performed well for most of the tube except some localized areas that the overlay was worn off. This localized area was apparently subject to high abrasive and erosive conditions and the HF35 weld overlay, with about RC35-40, was found to be inadequate.
An existing Fe—Cr—C hardfacing alloy weld overlay that can be weld overlaid to a part without stress cracks exhibits only moderate hardness. Thus, there is a need to develop a novel method to further increase the hardness of this moderately hardened hardfacing weld overlay to a level, such as RC50 or higher, such that the weld overlay's resistance to abrasive and/or erosive wear becomes adequate for use in aggressive abrasive and erosive environments.
In a test program trying to determine whether the HF35 overlay would be susceptible to cracking when the overlay was heated to very high temperatures, such as 2000° F., an HF35 overlay tube sample was furnace heated to 2000° F. and held for about one hour followed by furnace cooling to 1600° F. and then removed from the furnace and air cooled to room temperature. It was unexpectedly discovered that the overlay, which exhibited hardness of RC40 before this heat-treatment, was hardened to RC54 after this heat-treatment. This was a significant increase in hardness for the weld overlay produced by this simple heat-treatment. It was also discovered that this heat-treatment did not cause cracking of the hardfacing weld overlay. To see whether air cooling from 1600° F. to room temperature was responsible for this hardening, a sample of another HF35 overlay tube was placed in a 1600° F. furnace and the temperature was increased to 2000° F. by a furnace heat-up. The sample was held at 2000° F. for one hour and then furnace-cooled to 1600° F. and then continued to room temperature by furnace cooling. Significant hardening was also observed by this very slow furnace cooling. Hardness was increased from RC38 in the as-overlaid condition to RC54 after this heat-treatment with very slow furnace cooling. Thus, the hardening was not the result of well-known phase transformation to martensite during cooling to room temperature.
SUMMARY
Fe—Cr—C alloys that contain carbon content lower than about 2.0% such that the hardfacing alloy can be applied as a weld overlay without suffering stress cracks that are commonly encountered in high carbon (more than 2%) Fe—Cr—C hardfacing alloys. This type of lower carbon Fe—Cr—C hardfacing alloy weld overlay typically exhibits moderate hardness (about RC35-40), thus exerting only moderate resistance to erosion and abrasive wear. Thus, there is a strong need to further harden the weld overlay of this type hardfacing alloy after the application of the weld overlay to further increase its hardness to more than RC 50 in order to further increase its erosion and abrasive wear resistance.
In many industrial applications, many components, such as boiler tubes in a coal-fired boiler, are a pressure boundary, and a weld overlay that is applied to these components for erosion and/or abrasive resistance is required to be crack-free in order to avoid the propagation of the crack into this pressure boundary component potentially causing fatalities and injuries. Most Fe—Cr—C hardfacing alloys contain more than 2% carbon readily develop stress cracks when applied as a weld overlay. However, when carbon is reduced to a lower level to allow weld overlays of this group of hardfacing alloys to be applied, the hardness of the weld overlay was significantly reduced, thus resulting in significantly lower erosion and abrasive resistance. Thus, it is critically important that a method be provided to harden the weld overlay after it is applied to significantly increase its hardness to a more useful range through a simple heat-treatment.
In the present disclosure, there is provided a heat-treatment method by heating the weld overlay of this type of hardfacing alloy to a temperature of 2000° F. followed by air cooling or very slow furnace cooling will cause the hardness of HF35 weld overlay to increase from about RC 38 to RC 54. Both air cooling and very slow furnace cooling produced the same degree of hardening. This hardening is not the result of a well-known phase transformation involving formation of martensite and/or bainite observed in prior art involving Fe—Cr—C hardfacing alloys.
Heat treatments to 1800° F. and 1600° F., followed by air cooling produced a hardness increase to RC57 and RC56, respectively. The 1400° F. heat treatment produced somewhat lower hardening with a hardness increase to about RC51. Heat treating to 1200° F. produced no hardening is produced. The hardness of the weld overlay remained RC38, essentially same as that of as-overlaid condition.
The optimum heat treatment temperature is 1600° F. followed by air cooling. This will have less energy consumption by heat treating at the lowest temperature and less oxidation for substrate steels when heated to high temperatures. Heat treatment to 1400° F., although not achieving the same degree of hardening as compared with higher temperature heat-treatments, still results in quite substantial hardening. The heat treatment at 1400° F. makes the field heat-treatment possible when the overlay is applied in the field in such components as vessels and piping.
The range of hardening temperatures in the present disclosure is summarized in FIG. 2 . For HF35 weld overlay, hardening occurs at the heat-treatment temperatures of 1400° F. and higher, and up to 2000° F. At temperatures of 1600 to 2000° F., no significant differences in the degree of hardening. The temperature of 1600° F. is the optimum heat-treatment temperature in terms of energy savings and the least oxidation attack on substrate carbon or low alloy steels during the heat-treatment cycle. No hardening was observed at low heat-treatment temperatures, such as 1200° F.
The hardening obtained by heat-treatments in the present disclosure is not the result of a well-known hardening mechanism of martensite or bainite formation during cooling from the heat-treatment temperature. The hardening is the result of the formation of hard particles in the grain matrix at heat treating temperatures from 1400-2000° F. This is illustrated by comparing the microstructure of the as-overlaid HF35 weld overlay consisting of only eutectic carbide phases along the interdendritic boundaries, as shown in FIG. 3 , and that of the heat-treated overlay consisting of not only eutectic carbide phases along interdendritic boundaries but also hard precipitate phases within grain matrix, as shown in FIG. 4 . These hard precipitate phases that form within the grain matrix during the heat-treatment are believed to be responsible for the additional hardening during the heat-treatment.
BRIEF DESCRIPTION OF DRAWINGS
The foregoing aspects and advantages of present disclosure will become more readily apparent and understood with reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 illustrates the cross-section of a HF35 overlay tube sample consisting of an outer layer of HF35 overlay on a carbon steel tube
FIG. 2 illustrates the hardness (RC) of the weld overlay of HF35 hardfacing alloy as a function of the heat-treatment temperatures (1200, 1400, 1600, 1800 and 2000° F.) as compared with the as-overlaid condition indicated here as 70° F.
FIG. 3 illustrates the microstructure of the as-overlaid HF35 overlay (RC38) before the heat-treatment, showing eutectic carbide phases formed along interdendritic boundaries. Original magnification: 1000× (1000 times).
FIG. 4 illustrates microstructure of the HF35 overlay (RC54) after the heat-treatment at 2000° F. for one hour, showing numerous precipitates (dark particles) formed within the grain matrix. The eutectic carbide phases formed along intedendritic boundaries.
FIG. 5 illustrates microstructure of the HF35 weld overlay after heat-treatment to 1200° F., showing no precipitates formed within the grain matrix and thus no additional hardening by the heat treatment.
DETAILED DESCRIPTION
In power boilers, carbon or low alloy steels are typical construction materials for furnace boiler tube waterwalls and superheaters/reheaters in the convection section. The outer surface of these tubes is subject to high temperature corrosive combustion products, particulate erosive matter, thermal cycling and other hostile conditions. As a result of these aggressive boiler operating conditions, carbon and low alloy steel tubes suffer high wastage rates, thus requiring frequent replacements in many critical areas. Frequent shutdowns for the boiler due to materials problems can pose a serious issue of boiler availability and maintenance cost if protection methods are not utilized.
One cost-effective protection method for these boiler tubes is to use weld overlay tubes in those critical areas where unprotected carbon or low alloy steels suffer a short service life. The weld overlay is made by applying a corrosion- or erosion/corrosion-, or erosion-resistant weld overlay onto a carbon or low alloy steel tube. The overlay is typically applied onto a rotating tube using a gas-metal-arc (GMAW) welding method. The overlay applied in this spiral mode exhibits a uniform overlay around the tube circumference on the outer diameter of the tube. Thus, the weld overlay is capable of providing the needed resistance to corrosion, erosion-corrosion, or erosion for the boiler tubes in power boilers. The type of weld overlay alloy applied will depend on the nature of the tube wastage mechanism and the type of the boiler. For the area that requires an overlay for erosion or abrasion resistance, a hardfacing overlay material, such as HF35 alloy, would be required for the weld overlay. FIG. 1 shows a cross-section of a HF35 weld overlay tube. The weld overlay is applied onto the outer diameter surface of a tube. In refinery or petrochemical plants, the inner diameter (ID) of the tube or pipe may suffer corrosion, or erosion-corrosion, or erosion attack. Under these conditions, the weld overlay can also be applied on the ID surface of the tube or pipe. The manufacturing of weld overlay tubes is typically performed by overlay welding with water cooling in order to minimize the distortion of the tube from the heat input by welding. Overlay welding can also be applied onto a waterwall panel that consists of tubes with membranes connecting adjacent tubes. Field application of a weld overlay on the waterwall of a boiler or the wall of a pressure vessel is also routinely performed. The waterwalls surround the furnace and consist of a series of tubes with membranes connecting adjacent tubes. Water inside the tubes converts the heat generated in the furnace to high pressure steam for power generation. Overlay welding can be applied using automatic welding machines or by manually using a semi-automatic machine. Overlay welding can also be performed without water cooling when such set-up is not possible. Overlay welding can be applied using gas-metal-arc welding (GMAW), gas-tungsten-arc welding (GTAW), or other welding and cladding methods including Laser cladding and melting. Other arc welding methods may include submerged arc welding, electrostag welding and plasma transfer arc welding. The hardfacing alloys can also be manufactured in castings.
HF35 alloy is a Fe—Cr—C hardfacing weld wire comprising about 0.8-1.2% carbon, 1.0-2.0% manganese, 1.0-2.0% silicon, 20.0-23.0% chromium, 2.5-3.5% nickel, 0.2-0.5% zirconium, 0.5-1.0% molybdenum, and the balance iron along with residual elements and incidental impurities. The HF35 weld overlay of a weld overlay tube, which is produced by spiral overlay welding with component water cooling ( FIG. 1 ), typically contains about 1% carbon, about 19% chromium, about 2.5% nickel, about 0.5% molybdenum, about 1.4% manganese, about 1.2% silicon, about 0.3% zirconium, and balance iron.
In trying to determine whether the HF35 overlay would be susceptible to cracking when the overlay was heated to very high temperatures, such as 2000° F., an HF35 overlay tube sample was heated to 2000° F. by first placing the sample in the 1600° F. furnace and then furnace-heated to 2000° F. The sample was then held inside the furnace at 2000° F. for about one hour, followed by furnace cooled to 1600° F. and then removed from the furnace and air cooled to room temperature. It was unexpectedly discovered that the HF35 overlay, which exhibited hardness of RC40 before this heat-treatment, was hardened to RC54 after this heat-treatment. Examination of the microstructure of the hardened HF35 weld overlay after the 2000° F. heat-treatment revealed fine precipitate particles formed in the matrix in addition to the eutectic carbides that formed along the interdendritic boundaries. These fine precipitate particles were not in the as-weld overlay sample prior the heat-treatment. It is, thus, believed that these fine precipitate particles were responsible for additional hardening during the 2000° F. heat-treatment.
In order to confirm this unexpected discovery, another sample of HF35 overlay tube was subjected to the same heat-treatment as that stated in Paragraph [0028] (i.e., the sample was placed in the 1600° F. furnace, furnace-heated to 2000° F., held for one hour at the temperature, then furnace-cooled to 1600° F. followed by removing the sample from the furnace and air cooling it to room temperature. It was found that the hardness of the HF35 weld overlay was increased from RC 38 in the as-overlaid condition to RC 55 after the heat-treatment, thus essentially confirmed the previous unexpected discovery. The microstructure of this heat-treated weld overlay also showed precipitation of numerous fine particles in the matrix, similar to the microstructure observed in the earlier sample described in Paragraph [0028].
In order to determine whether the hardening occurred during air cooling from 1600° F. following the furnace cooling from 2000° F., another HF35 weld overlay tube sample, which was cut from the same HF35 weld overlay tube in the heat-treatment study described in Paragraph [0029], was placed in the 1600° F. furnace, furnace-heated to 2000° F., and held the sample for one hour at 2000° F., followed by a slow furnace cooling to room temperature by shutting off the furnace power. This slow furnace cooling would essentially eliminate any possibilities of forming martensite or bainite phases during cooling. The average hardness of the weld overlay after this slow furnace cool was found to be RC 54 (RC 56, 53, 53, and 53 across the overlay). The additional hardening was essentially same as the sample from air cooling, as described in Paragraph 0030.
Additional heat-treatments were performed to determine the temperature range that the hardening can occur. If the lower heat-treatment temperature can achieve the same hardening as was resulted from 2000° F. heat-treatment, energy saving can be resulted from a lower heat-treatment temperature. HF35 weld overlay tube samples were subjected to the following heat-treatments: 1800° F. for one hour followed by air cool, 1600° F. for one hour followed by air cool, 1400° F. for one hour followed by air cool, and 1200° F. for one hour followed by air cool. The average hardness of the weld overlay was found to be RC 57 (RC 57, 58, 56, and 56 across the overlay) heat-treated at 1800° F., RC 56 (RC 57, 56, 57, and 54 across the overlay) heat-treated at 1600° F., RC 51 (RC 56, 51, 50, and 48 across the overlay) heat-treated at 1400° F., and RC 38 (RC 39, 39, 37, and 36 across the overlay) heat-treated at 1200° F. The results show that heat treating at 1200° F. did not result in additional hardening. For additional hardening, temperatures higher than 1200° F. are required. Heat treating at 1400° F. shows some hardening, but for full hardening, temperatures higher than 1400° F. would be needed. The current heat treatment studies show that heat-treatments at 1600, 1800, and 2000° F. produced full hardening for HF35 weld overlay. The optimum heat treatment temperature in shop would be 1600° F. For field heat-treatments, the temperature can be 1400° F. or possibility of 1300° F. These low heat-treatment temperatures (i.e., 1400° F. or possibly 1300° F.) make the hardening heat-treatment possible in the field.
The compositional ranges for the Fe—Cr—C hardfacing alloy that is likely to produce additional hardening by the present heat-treatment disclosure are 0.5-2.0% carbon, 10-30% chromium, 1.0-8.0% nickel, 0.2-0.5% zirconium, 1.0-2.0% manganese, 0.5-3.0% silicon, 0.5-3.0% molybdenum, 0.0-3.0% tungsten, 0.0-0.5% boron, and balance iron along with impurities and incidental elements.
Table 1 shows the composition HF35 alloy. Also shown in the table is the exemplary compositional range of Fe—Cr—C hardfacing alloy that may also be utilized with the disclosed process.
TABLE 1
Nominal Chemical Composition in Weight Percent
EXEMPLARY
COMPOSITIONAL
HF35 COMPOSITIONAL
RANGE FOR DISCLOSED
ELEMENT
RANGE (WT. %)
ALLOY (WT. %)
C
0.8-1.2
0.5-2.0
Cr
20.0-23.0
10.0-30.0
Ni
2.5-3.5
1.0-8.0
Mn
1.0-2.0
1.0-2.0
Si
1.0-2.0
0.5-3.0
Zr
0.2-0.5
0.2-0.5
Mo
0.5-1.0
0.5-3.0
W
—
0.0-3.0
B
—
0.0-0.5
Fe
Balance
Balance
In other embodiments of the detailed disclosure, there exist other alloy compostions deviating either higher or lower than the compositions listed in Table 1 also benefiting from the heat treatments of the disclosed process.
While the above description contains many particulars, these should not be consider limitations on the scope of the disclosure, but rather a demonstration of embodiments thereof. The weld overlay hardening process and uses disclosed herein include any combination of the different species or embodiments disclosed. Accordingly, it is not intended that the scope of the disclosure in any way be limited by the above description. The various elements of the claims and claims themselves may be combined in any combination, in accordance with the teachings of the present disclosure, which includes the claims.
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A method of preparing a mechanical component with an Fe—Cr—C hardfacing weld overlay alloy for improving the resistance of the mechanical component to abrasion, erosion or erosion/corrosion for use in very abrasive, erosion or erosive/corrosive environments by significantly increasing the hardness of the weld overlay is disclosed. To improve the resistance to abrasion, erosion or corrosion, a weld overlay of a Fe—Cr—C hardfacing alloy is applied onto the surface of a metallic component, such as tubes, pipes, or vessels. Welding and cladding methods including gas-metal-arc welding (GMAW), gas-tungsten-arc welding (GTAW), and laser cladding may be utilized. Then, the component is heat-treated at elevated temperatures for a sufficient time, resulting in additional hardening and thus further increasing the weld overlay's resistance to abrasion, erosion, or erosion/corrosion.
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REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to European Patent Application No. 10012717.4-2301, filed on Oct. 1, 2010.
BACKGROUND
[0002] The invention relates to a service device for maintenance of a solar panel arrangement and a method for cleaning an inclined surface of a solar panel arrangement.
[0003] In the last years, the use of solar panels for the collection of solar energy and conversion into electrical energy has become a common practice. In solar power plants, large numbers of solar panels are mounted on supporting carriers and disposed in an array-like arrangement, usually forming long rows of solar panels neighbouring each other. In order to maximize the yield of collected solar energy, surfaces of the solar panels are aligned towards the sun and therefore inclined with respect to the horizontal. The angle of inclination may be kept fixed during the day, keeping the solar panels in an overall preferred position, or may be maintained in order to follow the sun. Contamination of the solar panel surfaces with dust, sand, snow, leaves and branches of plants, and other residues due to environmental influences are a known problem, causing reduction of the gained electrical energy. Therefore, periodic cleaning of the panel surfaces is necessary in order to achieve a high level of energy production. Besides this, there is further need for maintenance of solar panels especially in solar power plants, e.g. periodic examination of the panels for mechanical or electrical defects. However, manual maintenance like cleaning or examination of a large number of solar panels is costly in terms of time and labour. Furthermore, manual cleaning of solar panel surfaces is tedious work accompanied by physical exhaustion and inattentiveness of the workforce, eventually leading to fluctuations in terms of cleaning and inspection quality.
[0004] WO 2008 058 528 A1 describes a washing apparatus for cleaning of solar collectors and solar panels. The washing apparatus comprises an arc-shaped, stiff housing, inside which washing nozzles and brushes are arranged for cleaning a collecting surface of a solar collector. In use, the washing apparatus is mounted from above onto the collecting surface. The washing apparatus housing embraces the solar collector in its edge regions in such a way, that the washing apparatus is guided in a longitudinally movable manner directly on the solar collector. For that purpose, the housing comprises first rollers engaging with the surface to be cleaned and having a rolling axis parallel to the surface as well as second rollers engaging with the edge of the surface and having a rolling axis being perpendicular to the rolling axis of the first rollers. A disadvantage of the described washing apparatus is that due to embracement of the solar panel edges by the housing, the apparatus may be mounted or dismounted to rows of solar collectors only at free ends of the rows, rendering it impossible to mount or dismount the apparatus at arbitrary positions. A further disadvantage is that large masses of pollutants like snow or leaves cannot be handled by the washing apparatus due to the fact that all cleaning takes place in the confined space inside the housing of the apparatus. A further disadvantage with respect to solar panels is that parts of the housing encompass the edges of the surface to be cleaned and therefore may touch the sensitive backsides of solar panels, leading to serious damage of the solar panels.
[0005] EP 2 048 455 A2 describes an automatic cleaning system for solar panels. The system comprises longitudinal guiding rails being fixed to a supporting structure of the solar panels and being disposed on opposite sides of the solar panel arrangement to be cleaned. The system comprises further a cleaning brush being disposed orthogonally with respect to the guiding rails. Driving units are provided at both guiding rails for moving the cleaning brush along the guiding rails, thus cleaning the solar panel surfaces. A disadvantage of the described system is that separate, fixedly mounted guiding rails are necessary and that the cleaning brush is fixedly joined to the guiding rails. Accordingly, in a solar power plant comprising a large number of solar panel arrangements, an accordingly large number of guiding rails, driving units and cleaning brushes are necessary for cleaning of all solar panels, leading to high investment costs. Besides cleaning, no further maintenance is feasible with the described system.
[0006] EP 0 538 521 A1 describes a cleaning system for roof glazings. The system is designed for the cleaning of atrium-like glazings comprising triangular and trapezium shaped surfaces and pyramid like structures. The cleaning system comprises a first guiding reel being arranged above the glazing surface to be cleaned and a second guiding reel being arranged below the glazing. An extensible brush for cleaning the glazing is guided between the first guiding reel and the second guiding reel. Driving units for driving a corresponding end of the brush along the guiding reel are assigned to each guiding rail. In order to clean e.g. a trapezium shaped window, the window region to be cleaned may be partitioned into a rectangular section and one or two triangular sections. In order to clean the rectangular section, both ends of the brush are driven along the guiding rails in such a way that the brush is oriented perpendicular with respect to the guiding rails. In order to clean a triangular section, one of the ends of the extensible brush is kept in a fixed position, while the other end is driven along the corresponding guiding rail in order to cover the triangular surface. During this movement, the extensible brush changes its length. A disadvantage of the described system is that it comprises fixedly mounted guiding rails and that the cleaning brush is permanently joined to the guiding rails.
[0007] DE 10 2006 053 704 A1 considered to be the closest prior art describes a device for maintenance of a solar panel arrangement, comprising a service unit for maintenance of the solar panel arrangement, the service unit bridging the complete width of the solar panel and covering it with a housing. A guiding unit is provided at opposite ends of the housing, each guiding unit being configured as longitudinal groove of the housing extending along the solar panel arrangement and engaging the edge and a rear side of the solar panel arrangement. The service unit comprises a driving unit for moving the service unit along the solar panel arrangement.
SUMMARY
[0008] It is an object of the invention to provide a service device for maintenance of solar panel arrangements and a method for cleaning an inclined surface of a solar panel arrangement which is flexible in use and which allows removal of large amounts of dirt and/or snow.
[0009] It is a further object of the invention to provide an easy and effective maintenance of solar panel arrangements.
[0010] It is a still further object of the invention to provide a maintenance tool for cleaning solar panels that can easily be used for large solar plants and the like necessitating few or no assembly effort.
[0011] It is a still further object of the invention to provide a servicing device appropriate for substantially automated cleaning of large surfaces of solar aligned panels.
[0012] These and other objects are achieved according to a first aspect of the invention by a service device for maintenance of a solar panel arrangement, comprising a service unit for maintenance of at least one surface of the solar panel arrangement, a guiding unit for guiding the service unit with respect to the solar panel arrangement, the guiding unit being configured for direct engagement with an edge of the solar panel arrangement, and a driving unit for moving the service unit with respect to the solar panel arrangement, wherein the service unit comprises a first engagement section and a second engagement section, wherein the guiding unit is attachable to the first engagement section, wherein the driving unit is attachable to the second engagement section, and wherein the second engagement section is displaceable with respect to the first engagement section by the driving unit.
[0013] These and other objects are achieved according to a second aspect of the invention by a solar panel service apparatus for maintenance of substantially solar aligned surfaces of a plurality of a solar panels, comprising a service unit for maintenance of a solar aligned surface of at least one of the plurality of solar panels, a guiding unit for guiding the service unit along an edge of the solar aligned surface, the guiding contacting said edge, and a first driving unit for moving the service unit with respect to the solar aligned surface, wherein the service unit comprises a first engagement portion and a second engagement portion, the first engagement portion and the second engagement being substantially arranged at opposite ends of the service unit, wherein the guiding unit is attached to the first engagement portion, wherein the first driving unit is attached to the second engagement portion, wherein the guiding unit comprises a second driving unit for moving the service unit with respect to the solar aligned surface, and wherein the first driving unit and the second driving unit are driven independently from each other such that the service unit may change its orientation.
[0014] These and other objects are achieved according to a further aspect of the invention by a service device for maintenance of an inclined surface of a solar panel arrangement, comprising a service unit having a lower portion with a drive unit and an upper portion with a guide unit, wherein the guide unit is configured to engage an upper edge of one of a solar panel and a solar panel frame of the solar panel arrangement such that the upper edge defines a direction of motion of the service unit, wherein the drive unit is configured to displace the lower portion of the service unit with respect to the surface of the solar panel in order to adjust an angle between the service unit and the direction of motion of the service unit, and wherein the drive unit is driving the service unit in the defined direction of motion in such a way that the displacement of the upper portion and the displacement of the lower portion of the service unit with respect to the direction of motion is maintained.
[0015] These and other objects are achieved according to a further aspect of the invention by a service device for cleaning at least one surface surface of a solar panel arrangement, comprising a service unit comprising at least one cleaning unit for cleaning at least a region of the at least one surface, a guiding unit for guiding the service unit with respect to the solar panel arrangement, the guiding unit being configured to be supported on an edge of the solar panel arrangement, and a driving unit for moving the service unit with respect to the solar panel arrangement, wherein the guiding unit is attached to a first engagement section of the service unit, wherein the driving unit is attached to a second engagement section of the service unit, and wherein the at least one cleaning unit is arranged between the first engagement section and the second engagement section.
[0016] These and other objects are achieved according to a further aspect of the invention by a method for cleaning an inclined surface of a solar panel arrangement, comprising the steps of (1) engaging an upper section of a service unit with an upper edge of one of a solar panel and a solar panel frame of the solar panel arrangement such that the upper edge defines a direction of motion of the service unit, (2) displacing a lower section of the service unit with respect to the surface of the solar panel in order to adjust an angle between the service unit and the direction of motion of the service unit, and (3) driving the service unit in the defined direction of motion in such a way that the displacement of the upper section and the lower section of the service unit with respect to the direction of motion is maintained.
[0017] Due to the configuration of the guiding unit to be directly engaged with an edge of the solar panel arrangement, the service device is connectable to any type of solar panel arrangement without the need to provide guiding rails or the like for supporting the service device. Preferably, the service device is mounted onto the solar panel arrangement by simply latching the guiding unit into the edge of the solar panel arrangement. This advantageously allows for mounting the service device at any arbitrary position of the solar panel arrangement, greatly simplifying the mounting procedure as compared to conventional service devices. It further allows use of the service device with a large number of solar panel arrangements by simply dismounting the service device from a first solar panel arrangement by unlatching the guiding unit and remounting the service device to a second solar panel arrangement by latching the guiding unit to an edge of the second arrangement. Preferably, the edge of the solar panel arrangement is formed by an upper edge of at least one of the solar panels. In the context of this application, the terms “upper” and “lower” refer to the direction of gravity. Given a typical inclination of the solar panel surfaces with respect to the horizontal, the engagement of the guiding section with an upper edge of the solar panel arrangements provides a proper support for the service device. For directly engaging the edge of the solar panel, the panel may be of framed or frameless type. It must be understood that the edge of the solar panel arrangement may also be formed by a suited part of a supporting structure of the solar panel arrangement.
[0018] The first engagement section and the second engagement section of the service unit are advantageously both located at respective ends of the service unit, such that the ends of the service unit are supported by the guiding unit and the driving unit respectively.
[0019] Displacement of the second engagement section of the service unit with respect to the first engagement section of the service unit advantageously allows for alignment of the service unit with respect to the solar panel arrangement and a direction of movement of the service device. Particularly for cleaning the solar panel surface from large amounts of pollutants like snow, it is useful to align the service unit at an angle with respect to the plumb line, such that detached snow may directly fall off the panel surface due to gravity. Furthermore, an angled alignment of the service unit simplifies the passage of the service device from one solar panel to a neighbouring solar panel, since the guiding unit and the driving unit are accordingly displaced with respect to the edges of the panels.
[0020] Preferably, the guiding unit comprises driving means for moving the service unit with respect to the solar panel arrangement. This allows for reliable transport of the service device with respect to the solar panel arrangement and adjustment of the service unit alignment, since the engagement sections of the service unit are respectively moveable by the driving unit and the guiding unit independently. Alternatively, the guiding unit comprises means for fixing the position of the guiding unit with respect to the solar panel arrangement. In this configuration, a relative displacement of guiding unit and driving unit may be adjusted by fixing the guiding unit and moving the driving unit, while a movement of the service device is achieved by fixing an attachment angle between the guiding unit and the service unit and moving the driving unit.
[0021] Expediently, at least one of the guiding units and driving units comprises means for measuring a relative displacement of the first engagement section and the second engagement section with respect to a direction of motion of the service unit, allowing control of the alignment of the service unit during movement of the service device.
[0022] In a preferred embodiment, the means for measuring the relative displacement comprise means for measuring an attachment angle between the service unit and the at least one of the guiding units and the driving units. The means for measuring the attachment angle may in particular comprise a Hall sensor.
[0023] Preferably, the service unit comprises at least one service element selected from the group comprising a brush being rotatable with respect to the surface of the solar panel arrangement, a brush being fixed with respect to the surface of the solar panel arrangement, a wiper engaging the surface of the solar panel arrangement, a snow plough, a cleaning agent applicator, a sprinkling unit, a washing unit, a rubbing unit, a suction unit for removing residual water and/or cleaning agents, a polishing unit, an optical and/or electronic reader device and an optical sensor for inspection of the solar panel arrangement. The rotating and/or fixed brushes and the wiper are especially useful for detaching and removing dirt from the solar panel surface. Additionally, a snow plough service element provides the possibility to remove large masses of snow or other heavy pollutants. The cleaning agent applicator for applying water and/or chemical and/or biological cleaning supplies further enhances cleaning of the solar panel surfaces. Sprinkling units, washing units and/or rubbing units may be used sole or in combination to execute different cleaning tasks in varying intensity. Expediently, a suction unit for removing residual water and/or cleaning agents is used for removal of residual fluids and the comprised pollutants therein as well as for drying the cleaned surface. The polishing unit is useful for polishing the solar panel surfaces, thus enhancing the production of electrical energy and/or allowing for the application of long-lasting coatings to the panel surfaces. The optical and/or electronic reader device may be used inter alia to identify individual solar panels by reading information being printed or otherwise embedded on the solar panel surface. The optical sensor for inspection of the solar panel arrangement may be used to identify mechanical and/or electrical defects of the solar panels. Combined with the optical and/or electrical reader device, individual maintenance information for each solar panel may be computed and stored for further review in the service device.
[0024] Advantageously, the service device may comprise at least one further service unit. In advantage, the service devices combine two or more of the above mentioned service elements to accomplish two or more maintenance functions in a single working step.
[0025] In a preferred embodiment, the guiding unit comprises guiding wheels engaging the edge of the solar panel arrangement and traction means for engaging the surface of the solar panel arrangement. The traction means may comprise driving wheels, driving belts, driving chains and the like. Preferably, the weight of the service device is partly born by the guiding wheels and partly born by the traction means and the driving unit.
[0026] Preferably, the service device further comprises a control system being configured to adjust a relative displacement of the first engagement section and the second engagement section of the service unit with respect to a direction of motion of the service unit.
[0027] Expediently, the surface of the solar panel arrangement may be inclined with respect to the horizontal.
[0028] According to the invention, the method for cleaning an inclined surface of a solar panel arrangement comprises the steps of engaging an upper section of a service unit with an upper edge of a solar panel or a solar panel frame of the solar panel arrangement such that the upper edges define a direction of motion of the service unit, displacing a lower section of the service unit with respect to the surface of the solar panel in order to adjust an angle between the service unit and the direction of motion of the service unit, and driving the service unit in the defined direction of motion in such a way that the displacement of the upper section and the lower section of the service unit with respect to the direction of motion is maintained. This method allows for reliable cleaning of solar panel surfaces by dropping detached pollutants directly to the ground as well as achieving exact alignment of the service unit with respect to solar panel edges in particular for inspection purposes.
[0029] Expediently, the angle between the service unit and the direction of motion is adjusted such that deposits on the surface are pushed at least partially into the direction of gravity.
[0030] Advantageously, the service device is controlled in such a way that during motion no part of the service device comes into physical contact with the rear of the solar panels. By this, damage to the sensitive rear of the solar panels is safely avoided.
[0031] According to a first preferred embodiment of the method, driving of the service unit is remotely controlled. According to a second, alternative embodiment of the method, driving of the service unit is autonomously controlled.
[0032] Further advantages and features of the invention will become more apparent from a detailed consideration of the exemplary embodiments described hereinafter.
[0033] Three preferred exemplary embodiments of a service device according to the invention are described hereinafter and explained in more detail with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 shows a schematic view of a first embodiment of a service device according to the invention.
[0035] FIG. 2 shows a perspective view of the service device of FIG. 1 .
[0036] FIG. 3 shows a detailed view of a guiding unit of the service device of FIG. 1 .
[0037] FIG. 4 shows a schematic view of a second embodiment of a service device according to the invention.
[0038] FIG. 5 shows a perspective view of the service device of FIG. 4 .
[0039] FIG. 6 shows a schematic view of a third embodiment of a service device according to the invention.
DETAILED DESCRIPTION
[0040] FIGS. 1-3 show a first embodiment of a service device 1 for maintenance of a solar panel arrangement 2 . The solar panel arrangement 2 comprises solar panels 3 , which are mounted on a supporting carrier (not shown). A large number of solar panels (of which only a first solar panel 3 is shown in FIG. 1 and FIG. 2 ) are arranged in a row-like manner in the horizontal direction to form the solar panel arrangement 2 . Usually, several of such rows of solar panels form a solar power plant. Each of the solar panels 3 comprises a large number of solar cells for conversion of solar energy into electrical energy, said solar cells being located on an upward facing surface 11 of the solar panel 3 . The solar panel 3 is arranged in such a way, that the surface of solar panel 3 is inclined with respect to a horizontal plane. Accordingly, solar panel 3 comprises (with respect to the plumb line) an upper edge 4 and a lower edge 5 .
[0041] The service device 1 comprises a guiding unit 6 , a driving unit 7 and a service unit 8 being configured as a rotatable cleaning brush (as can be seen best in FIG. 1 ; in FIG. 2 , service unit 8 is shown only schematically). The guiding unit 6 is engaged with the upper edge 5 of the solar panel 3 and comprises a set of three guiding rollers 9 being supported by a side surface of the upper edge 5 and a traction belt 10 being supported by the upward facing surface 11 of the solar panel 3 . Due to the inclination of solar panel 3 with respect to the horizontal, the guiding rollers 9 and traction belt 10 respectively bear partly the weight of guiding unit 6 and service unit 8 . The guiding unit 6 further comprises a gear and driving system 12 for driving traction belt 10 , a plurality of driving rollers 13 supporting traction belt 10 and a tensioning adjustment 14 being configured to adjust a tensioning of traction belt 10 . By operating the gear and driving system 12 , a circulation of traction belt 10 around the driving rollers 13 is drivable. Thereby, guiding unit 6 can be selectively moved in one of the two directions parallel to the upper edge 4 of the solar panel 3 . In this process, the movement of guiding unit 6 is guided by the guiding rollers 9 . Although the embodiment of the guiding unit 6 shown in FIG. 1 and FIG. 2 comprises a set of three guiding rollers 9 , it must be understood that any other suited configuration of guiding rollers and/or any other suited kind of guiding members like e.g. rolling members, sliding members and the like may be used to support the guiding unit 6 on a side surface and/or up facing surface of the solar panel 3 .
[0042] A first engagement section 15 located at a first end of the service unit 8 is pivotably connected to the guiding unit 6 . The guiding unit 6 comprises a prime mover 16 , which is connected to a corresponding receiving element located at the service unit 8 . Service unit 8 as shown in FIG. 1 is configured as a rotational brush, wherein a rotational movement of the brush is driveable by prime mover 16 . Depending on the kind of service unit connected to the guiding unit 6 , different sequences of motion for driving the service unit may be passed from the prime mover 16 to the service unit 8 . By operating the gear and driving system 12 , driving unit 7 can be selectively moved in a direction parallel to the upper edge 4 and the lower edge 5 of the solar panel 3 . The trajectory of driving unit 8 is thereby positively controlled by the service unit 8 and guiding unit 6 .
[0043] A second engagement section 17 of service unit 8 , located at a second end of service unit 8 , is pivotably connected to the driving unit 7 . Driving unit 7 is constructed in a way structurally comparable to guiding unit 6 , but does not comprise guiding rollers. Accordingly, driving unit 7 comprises a traction belt 10 , a gear and driving system 12 , a plurality of driving rollers 13 supporting traction belt 10 , a tensioning adjustment 14 and a prime mover 16 being connected to service unit 8 .
[0044] Both the guiding unit 6 and the driving unit 7 comprise a measuring apparatus (not shown) for measuring the attachment angle between the service device 8 and the guiding unit 6 and the driving unit 7 respectively. The measuring apparatus comprises a Hall sensor for detecting the relative position of service device 8 and guiding unit 6 and driving unit 7 respectively, although it has to be understood that every suitable measuring apparatus for measuring the orientation of the service unit 8 may be used. It further has to be understood that the measuring apparatus used may be configured to measure either one or both of the attachment angles between the service device 8 and the guiding unit 6 and the driving unit 7 respectively. The service device 1 further comprises a control device for controlling movement of the guiding unit 6 and the driving unit 7 independently. Inter alia, the measured attachment angle between the service unit 8 and guiding unit 6 is used as an input signal for operating service device 1 . The control device may be configured to operate service device 1 autonomously or remotely controlled.
[0045] The service device 1 may be operated in the following way:
[0046] In order to clean solar panels 3 of the solar panel arrangement 2 , a service unit 8 configured as a cleaning unit (e.g. the rotatable brush as described above) is connected to the guiding unit 6 and the driving unit 7 in order to form the service device 1 . Afterwards, the service device 1 is mounted on the solar panel 3 by engaging guiding unit 6 to the upper edge 4 of solar panel 3 . By selectively moving the guiding unit 6 and/or the driving unit 7 , the orientation of the service device 8 is adjusted. For example, for cleaning the surface 11 of solar panel 3 , an orientation of service device 8 perpendicularly to the upper edge 4 of solar panel 3 may be selected. Afterwards, by constantly driving the guiding unit 6 and driving unit 7 , service unit 8 is moved in a direction parallel to the upper edge 4 of solar panel 3 , sweeping over the surface 11 of solar panel 3 . Thereby, the overall movement of the service device 1 is guided by the cooperation of the guiding rollers 9 of guiding unit 6 and the upper edge 4 of solar panel 3 . In case of large amounts of dirt, snow or the like being deposited on the surface 11 , the orientation of the service unit 8 is changed: in this case, driving unit 7 is displaced backwardly with respect to guiding unit 6 , such that the angle between the upper edge 4 of solar panel 3 and the service unit 8 opened in the direction of travel is larger than 90 degrees. Thereby, pollutions of the surface 11 lifted off by the service unit 8 are not only moved into the direction of travel of the service device 1 , but also—accelerated by gravity—additionally moved towards the lower edge 4 of solar panel 3 . In order to optimize the cleaning result, the orientation of the service device 8 is maintained during the complete cleaning operation. After cleaning of the solar panel surface, the service device 1 is lifted off from the solar panel arrangement 2 and may be transported to another solar panel arrangement to continue cleaning. Alternatively, the service unit 8 may be replaced by a different service unit, e.g. an optical sensor unit, for further maintenance of the solar panel arrangement 2 such as inspection for mechanical and/or electrical defects.
[0047] FIGS. 4 and 5 show a second embodiment of a service device 101 for maintenance of a solar panel arrangement 102 . Compared to the first embodiment shown in FIGS. 1-3 , reference numbers of analogue parts or equivalently working parts are incremented by 100.
[0048] Compared to the first embodiment, the guiding unit 106 of the service device 101 according to the second embodiment comprises two sets of guiding rollers 109 and two sets of driving apparatus, i.e. two traction belts (not shown in FIG. 5 ) and two gear and driving systems 112 . Likewise, the driving unit 107 comprises two driving apparatus. Therefore, the guiding unit 106 and the driving unit 107 respectively offer a much longer extension into their direction of motion. Particularly, the respective extension of the guiding unit 106 and the driving unit 107 is large compared to a gap 120 between neighbouring solar panels 103 of the solar panel arrangement 102 . Therefore, a safe passage of the service device 101 from one solar panel 103 to a neighbouring solar panel 103 is easily enabled.
[0049] As can best be seen from FIG. 5 , the service unit 108 of the service device 101 according to the second embodiment is designed as an optical sensor for scanning the surface of solar panels 3 . However, it has to be understood that the service unit 108 may be replaced by any other suitable service unit, e.g. a cleaning brush, a wiper, a snow plough, a cleaning agent applicator, a polishing unit or an optical and/or electronic reader device. Again, an optimal alignment of the service unit 108 with respect to the direction of motion may be obtained by adjusting a displacement between the guiding unit 106 and the driving unit 107 .
[0050] FIG. 6 shows a third embodiment of a service device 201 for maintenance of a solar panel arrangement 202 . Compared to the first embodiment shown in FIGS. 1-3 , reference numbers of analogue parts or equivalently working parts are incremented by 200.
[0051] The service device 201 comprises an additional service unit 228 , such that supplemental maintenance functions may be accomplished within one work step, i.e. one passage of the service device 201 over the solar panel arrangement 202 . The service units 208 , 228 may be chosen to complement each other, e.g. by choosing a brushing unit and a cleaning agent applicator, or may be chosen to obtain different tasks in one working step. Again, an optimal alignment of the service units 208 and 228 with respect to the direction of motion may be obtained by adjusting a displacement between the guiding unit 206 and the driving unit 207 .
[0052] It has to be understood that the above described constructional elements of the service device may be combined not only in the described way, but in many more ways being apparent to a person skilled in the art. In particular, a service device may comprise a multitude of guiding units and/or driving units and/or service units. For example, for building up a service device spanning a large vertical distance, a first service unit may be engaged with a guiding unit at its upper end and with a first, intermediate driving unit at its lower end. Afterwards, a second service unit is engaged at its upper end with the first, intermediate driving unit and at its lower end with a second, lower driving unit.
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The invention relates to a service device for maintenance of a solar panel arrangement, comprising a service unit for maintenance of at least one surface of the solar panel arrangement, a guiding unit for guiding the service unit with respect to the solar panel arrangement, and a driving unit for moving the service unit with respect to the solar panel arrangement, wherein the service unit comprises a first engagement section and a second engagement section, wherein the guiding unit is attachable to the first engagement section, the guiding unit being configured for direct engagement with an edge of the solar panel arrangement, wherein the driving unit is attachable to the second engagement section, and wherein the second engagement section is displaceable with respect to the first engagement section by the driving unit.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to a method of etching a ferroelectric material. It more specifically relates to a method for etching a barium strontium titanate layer (BST), used in the fabrication of tunable capacitors.
[0003] 2. Description of the Related Art
[0004] In some specific structures, there is a need for the fabrication of tunable capacitors, the capacitance of which varies as a function of the applied voltage. To manufacture such capacitors, it has been proposed to use barium strontium titanate, (BaSr)TiO3, or BST, as a dielectric.
[0005] FIG. 1A shows such a capacitor during an intermediate manufacturing step. On a substrate 1 is formed a metallic layer 3 , generally of platinum. On this layer, a BST layer 5 has been deposited, itself covered with a photoresist 7 , in which an opening 8 has been formed by photolithography at the position where it is desired to form an opening 9 in the BST layer.
[0006] FIG. 1A shows the structure after photolithography 20 of layer 7 and etching of layer 5 . FIG. 1B is a top view of the structure at this step. The etching of the BST layer is conventionally performed using an acid etching solution of hydrofluoric acid and nitric acid. It can be noticed that the etching of the BST layer 5 suffers from several drawbacks. Firstly, the etching extends relatively far laterally under the photoresist layer 7 . The lateral etching may extend under layer 7 by up to five times the thickness of the BST layer. Secondly, this lateral etching is irregular, as shown in FIG. 1B , and some cracks 10 extend from the edge of the opening 9 into the BST layer. These cracks are responsible for infiltrations and may damage the dielectric properties of the BST layer where they appear. As a result, a capacitor manufactured in this way does not present desired characteristics.
BRIEF SUMMARY
[0007] One embodiment of the present disclosure is solves at least one of the drawbacks of the conventional methods of etching a BST layer.
[0008] A more specific embodiment of the present disclosure provides an etching solution providing a regular etching of a BST layer.
[0009] One embodiment of the present disclosure provides a method for etching a PVD deposited barium strontium titanate (BST) layer, wherein a non-ionic surfactant at a concentration between 0.1 and 1 percent is added to an acid etching solution.
[0010] According to an embodiment, the concentration of the surfactant is between 0.2 and 0.4 percent. According to an embodiment, the etching solution is an aqueous solution of hydrofluoric acid and nitric acid.
[0011] According to an embodiment, the surfactant is alkylphenoxy-polyglycidol. According to an embodiment, the BST layer lies on a platinum layer.
[0012] An embodiment of the present disclosure provides a tunable capacitor with a BST dielectric obtained by the above method.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] The foregoing and other features, aspects and advantages of the disclosure will become apparent from the following detailed description of embodiments, given by way of illustration and not limitation with reference to the accompanying drawings, wherein:
[0014] FIG. 1A , previously described, illustrates schematically an etched BST layer;
[0015] FIG. 1B , previously described, is a top view of the etched BST layer of FIG. 1A ;
[0016] FIG. 2A illustrates schematically an etched BST layer;
[0017] FIG. 2B is a top view of the etched BST layer of FIG. 2A .
[0018] For clarity, the same elements have been designated with the same reference numerals in the different drawings, and furthermore, as is usual in the representation of semiconductor components, the various drawings are not to scale.
DETAILED DESCRIPTION
[0019] FIG. 2A is a cross section illustrating a tunable capacitor during an intermediate manufacturing step. On a substrate 1 , which is for example made of glass, sapphire, alumina, quartz or which is a silicon substrate covered with an isolating layer that constitutes the top layer of a structure, is formed a layer 3 of platinum that will form the lower electrode of the capacitor. On this layer, a sputtered BST film 5 has been formed by physical vapor deposition (PVD), itself covered with a photoresist layer 7 , in which an opening 8 has been formed by photolithography at the position where it is desired to form an opening 19 in the BST layer.
[0020] FIG. 2A shows the structure after photolithography of layer 7 and etching of layer 5 . FIG. 2B is a top view of the structure at this particular step. The etching of the BST layer has been performed by an acid etching solution that is a mixture of hydrofluoric acid and nitric acid in an aqueous solution, into which a non-ionic surfactant has been added. The surfactant is for example alkyl-phenoxy-polyglycidol, at a concentration between 0.1 and 1 percent, preferably between 0.2 and 0.4 percent by volume. The etching solution is for example obtained from a mixture of 1.6 liters of hydrogen fluoride (HF) solution at a concentration of 1 percent, 0.14 liter of HNO 3 solution at a concentration of 70 percent, and 26.25 liters of water.
[0021] The lateral etching of the BST layer is regular, as shown schematically by FIG. 2B , and the amount that this lateral etching of the BST layer extends under the photoresist layer 7 is roughly reduced by a factor 2 compared to the use of the same etching solution without surfactant. Additionally, no cracks 10 appear in the BST layer from the edge 19 of the opening formed in this BST layer.
[0022] Moreover, the inventors observed that the addition of a surfactant in the acid etching solution has no influence on the etch rate of the BST layer compared to the use of the same etching solution without surfactant. It is considered that the conservation of the etch rate is related to the conservation of the acidity levels of the etching solution thanks to the non-ionic nature of the surfactant used.
[0023] By conserving the BST etch rate as compared to the use of the same etching solution without surfactant, the man skilled in the art is able to re-use the know-how concerning the etching of the BST layer, while taking advantage of the benefits related to the method described herein.
[0024] The improvement in the lateral etching (thinner and more regular) is attributed to the fact that the surfactant forms aggregates (for example micelles), that obstruct the edge of the etching area under the photoresist layer.
[0025] For example, the dimensions of the opening in the photoresist layer may be chosen such that the opening in the BST layer is between several micrometers and several hundred micrometers across.
[0026] The disclosure is subject to various modifications, in particular as regards the acids usable for the etching solution. Various surfactants can also be used. The metallic layer 3 that supports the BST layer and will form the lower electrode of the capacitor can be formed of a metal other than platinum. However, it will be noted that the disclosure specifically applies to BST layers deposited by PVD, and not to BST layers resulting from a solgel coating. Also, one skilled in the art will recognize that a top electrode (not shown) will be formed on the BST layer either before or after the etching of the BST layer.
[0027] The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
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The disclosure concerns a method for etching a PVD deposited barium strontium titanate layer, wherein a non-ionic surfactant at a concentration between 0.1 and 1 percent is added to an acid etching solution.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application 61/423,153 filed Dec. 15, 2010, and the benefit of U.S. Provisional Application 61/521,178 filed Aug. 8, 2011 both hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to light emitting diodes and in particular to an improved heat sink assembly for high-powered light emitting diodes.
BACKGROUND OF THE INVENTION
[0003] High-powered light emitting diodes are increasingly replacing other light technologies, including incandescent and fluorescent lamps, for general illumination purposes. Such high-powered light emitting diodes accept currents in excess of 100 milliamps and typically at least one ampere to provide a light output for illumination of a space or area, for example, in an appliance such as a refrigerator or the like.
[0004] High-powered light emitting diodes normally require a heat sink to prevent destructive overheating. For this purpose, the light emitting diode will be placed on a carrier such as a printed circuit board holding conductive traces to connect the light emitting diode to other circuitry or power leads. The substrate may be attached to a heat sink, for example, of molded or extruded aluminum to conduct heat generated by the light emitting diode away from the diode into ambient air or other medium.
SUMMARY OF THE INVENTION
[0005] The present invention provides a high-powered LED assembly in which the LED is attached directly to the heat sink without the need for an intervening printed circuit board. By eliminating the thermal resistance of the substrate, improved cooling of the LED may be provided permitting higher power or longer life illumination systems. Electrical connection between the LED and a wiring harness is provided by a spring clamp system that both retains and attaches to a wire conductor and provides a positive electrical connection to a trace on the surface of the heat sink that may in turn attach to the LED.
[0006] Specifically, the present invention provides an LED assembly having a LED dissipating during operation at least 500 mW attached in thermal communication with the first surface of the ceramic heat sink. The LED is attached to a first and second conductive lead. A sealed housing receives the ceramic heat sink and LED therein and has a first portion fitting over the LED to permit the passage of light therethrough and a second portion providing for sealed ingress of the first and second electrical conductors through a housing wall for providing power to the LED. A compression element extends between a portion of the housing and ceramic heat sink to provide a predetermined range of biasing force, locating the ceramic heat sink against the portion of the housing with dimensional changes in the ceramic heat sink caused by thermal expansion of the ceramic heat sink.
[0007] It is thus a feature of at least one embodiment of the invention to provide for a fluid tight housing protecting and LED attached to a ceramic substrate that may accommodate thermal expansion of the substrate.
[0008] The first portion of the sealed housing may be a light-transmissive thermoplastic and the second portion of the sealed housing is a thermoplastic fused to the first portion. Similarly, the electrical conductors may have integral coaxial thermoplastic insulation and where the second portion of the sealed housing may be fused to the thermoplastic insulation.
[0009] It is thus a feature of at least one embodiment of the present invention to provide a simple method for producing a sealed housing amenable to mass production through injection molding.
[0010] The spring clamp may be a flexible metal ring.
[0011] It is thus a feature of at least one embodiment of the present invention to provide a fatigue resistant spring element that may handle multiple cycles of thermal expansion.
[0012] The first portion of the sealed housing may provide a ledge abutting a portion of the first surface of the ceramic heat sink and a collar extending around a portion of the ceramic heat sink behind the first surface and the spring clamp may include cantilevered teeth portions providing a wedging engagement with an inner surface of the collar to hold the flexible metal ring in abutment with a second surface of ceramic heat sink behind the first surface.
[0013] It is thus a feature of at least one embodiment of the present invention to provide a method of staking the components together prior to sealing of the housing that may make use of the spring element.
[0014] The metal ring may further include protrusions contacting the second surface and limiting the force applied thereto.
[0015] It is thus a feature of at least one embodiment of the present invention to control the maximum force is applied to the ceramic to prevent damage thereto. The protrusions limit maximum force and by providing a space between the ring and the ceramic allow greater compliancy of the spring force.
[0016] The first surface may include metal traces attached directly to the first surface and electrically communicating between the LED and first and second conductors.
[0017] It is thus a feature of at least one embodiment of the present invention to allow close integration of the LED to the ceramic substrate.
[0018] The metal traces may be printed conductive ink.
[0019] It is thus a feature of at least one embodiment of the present invention to provide a simplified electrical connection to the LED die possible in the sealed environment of the housing.
[0020] The ceramic may be Steatite.
[0021] It is thus a feature of at least one embodiment of the present invention to provide a readily manufactured ceramic material that is thermally conductive and yet electrically insulated.
[0022] The LED assembly may further include a first and second spring clamp insertable through apertures in the ceramic heat sink each having first portions, contacting different conductive traces when so inserted, and clamping elements receiving and retaining different of the first and second conductors.
[0023] It is thus a feature of at least one embodiment of the present invention to provide a method allowing electrical communication between wires and conductive traces with simple mechanical assembly.
[0024] The first portion of the spring clamps may be spring biased by the spring clamp against the conductive trace.
[0025] It is thus a feature of at least one embodiment of the present invention to provide a positive connection between a conductive material on the ceramic and a conductor, with thermal expansion and contraction of the ceramic.
[0026] The clamping elements of the spring clamps may provide flexible opposed spring elements slidably receiving ends of the conductors in electrical engagement.
[0027] It is thus a feature of at least one embodiment of the present invention to provide a simple connector-like attachment of conductive wires to the LED
[0028] Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a fragmentary perspective view of a ceramic heat sink used in the present invention supporting an LED die for direct mounting thereon and showing conductive metal traces attached to the ceramic surface;
[0030] FIG. 2 is a cross-sectional view along the line 2 -- 2 of FIG. 1 showing incorporation of the ceramic heat sink into a protective molded assembly;
[0031] FIG. 3 is an exploded, perspective fragmentary view of the top of the heat sink showing a spring clamp insertable into a slot in the heat sink;
[0032] FIG. 4 is a cross-section along line 4 -- 4 of FIG. 1 showing the spring clamp before insertion into the heat sink and the wire conductor before insertion into the spring clamp;
[0033] FIG. 5 is a detailed fragmentary view of FIG. 4 in unexploded form showing a spring biasing of the spring clamp to engage a trace on the surface of the heat sink;
[0034] FIG. 6 is a perspective partial cross-section view of an alternative embodiment of the invention employing a chip on board (COB) construction;
[0035] FIG. 7 is a perspective view and partial cross-sectional view of a compression element retaining the heat sink in the protective molded assembly while accommodating thermal expansion;
[0036] FIG. 8 is a figure similar to that of FIG. 1 showing alternative direct soldering connection of the conductors to traces on the heat sink;
[0037] FIG. 9 is a figure similar to that of FIG. 2 showing the direct soldering connection of FIG. 8 .
[0038] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Referring now to FIG. 1 , an LED assembly 10 per one embodiment of the present invention may provide for a ceramic substrate/heat sink 12 having an upper planar surface 14 supporting a high-powered LED 16 . The LED 16 may include conductive pads 18 attached to conductive traces 20 attached directly to the upper planar surface 14 of the ceramic substrate/heat sink 12 for example by printing. The conductive traces 20 may communicate from the conductive pads 18 to spring clamps 22 connected to power lead conductors 24 as will be described.
[0040] The ceramic substrate/heat sink 12 in one embodiment may be Steatite or soapstone that has been formed by a compression molding and fired to a high temperature to impart good thermal conductivity and high electrical resistance. Steatite is predominately a hydrated magnesium silicate. In one embodiment, the coefficient of thermal expansion of the ceramic substrate/heat sink 12 is approximately matched to that of the traces 20 and, for example, when the ceramic is Steatite, an L3 grade may be selected. The traces 20 are preferably formed of a silkscreened silver/platinum ink that is baked onto the surface of the ceramic substrate/heat sink 12 for improved adhesion.
[0041] The ceramic substrate/heat sink 12 extends away from the upper planar surface 14 to a fluted heat sink body portion 26 to provide thermal coupling to ambient air or the like through the increased surface area of fins according to well-known techniques.
[0042] Referring now to FIG. 2 , the LED assembly 10 may further provide a supporting package including a lens assembly 36 providing a hemispherical dome 37 over the LED 16 . The hemispherical dome 27 may be of transparent thermoplastic having dimensions that follow a portion of the sphere substantially centered on the LED 16 with a diameter slightly smaller than the upper planar surface 14 . A radially extending flange 38 may pass outward from the periphery of the hemispherical dome 37 having a lower surface substantially equal to the height of the upper planar surface 14 . This flange 38 may extend over a sheet-metal console 40 or the like having an opening size to accept the LED assembly 10 therein. Clips 42 may extend rearward from the bottoms of the flanges 38 to fit through the hole in the sheet-metal console 40 . The clips 42 provide a spring-loaded outward cantilevered arm to retain the LED assembly 10 against the sheet-metal console 40 , the latter sandwiched between a lower portion of the flange 38 and upper portion of each cantilevered arm of the clips 42 .
[0043] A cylindrical collar or socket 44 may also extend rearward from the flange 38 inside of the clip 42 to receive the upper planar surface 14 of the ceramic substrate/heat sink 12 therethrough. The periphery of the upper planar surface 14 of the ceramic substrate/heat sink 12 within the cylindrical socket 44 may abut against a lip 46 of the dome 37 . The ceramic substrate/heat sink 12 may present a flange surface 50 at the periphery of its rearward face that may receive a compression washer 52 fitting between the inner walls of the cylindrical socket 44 and the flange surface 50 to retain the ceramic substrate/heat sink 12 abutting the lip 46 .
[0044] Referring also to FIG. 7 , the compression washer 52 may be formed from a flexible metal sheet and may provide a ring 53 having outwardly splayed pawls 55 that operate to stake the compression washer 52 within the cylindrical socket 44 with a press-fitting operation so that the ring 53 closely abuts the flange surface 50 and the splayed pawls 55 are braced against the inner surface of the cylindrical socket 44 in the manner of a ratchet pawl to prevent shifting of the ring 53 away from the surface 50 . The ring 53 may provide for embossed dimples 57 that serve to limit the force of the compression washer 52 against the surface 50 and by providing a space between the ring 53 and the surface 50 , allow flexure of the compression washer 52 accommodate thermal expansion of the ceramic substrate/heat sink 12 within the sealed housing.
[0045] Referring again to FIG. 2 , a remainder of the cylindrical socket 44 beyond the flange surface 50 and compression washer 52 may be filled with a low temperature thermoplastic 59 such as nylon to seal out moisture from the dome 37 by fusing with the inner wall of the cylindrical socket 44 . The low temperature thermoplastic 59 may also be molded into strain relief arms 54 extending rearward along the conductors 24 to seal the conductors 24 by fusing with the insulation covering of the conductors 24 . The strain relief arms 54 have circumferential ribs providing controlled flexibility and limiting a radius of curvature of the bending of the conductors 24 .
[0046] A bridge of thermoplastic 56 between the strain relief arms 54 abuts a rear surface of the ceramic substrate/heat sink 12 to further prevent its disengagement.
[0047] Referring now to FIGS. 3 and 4 , the conductive traces 20 leading from the LED 16 may extend toward the periphery of the upper surface 14 toward two separated rectangular openings 60 extending downward into the surface 14 which may receive the power lead conductors 24 upward therethrough. A spring clamp 22 may be inserted into the rectangular openings 60 to provide electrical connection between the power lead conductor 24 and the conductive traces 20 for each lead of the LED 16 .
[0048] The spring clamp 22 may be formed from a single strip of metal such as a brass or bronze and provides an upper bridge 61 that will ultimately lie generally parallel to the upper surface 14 of the ceramic substrate/heatsink 12 and which has left and right legs 62 a and 62 b extending downward there from to fit into rectangular openings 60 . The width of the legs 62 (generally perpendicular to the long extent of the bridge 61 ) conforms to the width (shortest cross-sectional dimension) of the rectangular opening 60 and the separation of the legs 62 a and 62 b conform generally to the length (longest cross-sectional dimension) of the rectangular opening 60 so that the spring clamp 22 may fit snugly within the rectangular opening 60 .
[0049] The center of the bridge 61 provides a ring portion 64 which will be coaxial around the upward extending conductor 24 when the spring clamp 22 is in place in the rectangular opening 60 with the bridge 61 substantially flush against the top of the surface 14 and the conductor 24 engaged with the spring clamp 22 after passing upward through the ceramic substrate/heatsink 12 . The ring portion 64 includes left and right downwardly extending dimples 66 bisecting the ring portion 64 and the bridge 61 . The dimples 66 are separated from each other by a distance greater than the width of the rectangular openings 60 so as to straddle the rectangular openings 60 when the spring clamp 22 is in place in the rectangular opening 60 . One dimple 66 will contact the upper surface of the conductive trace 20 closest to the rectangular opening 60 and the other dimple 66 will contact the upper surface 14 directly on the opposite side of the rectangular opening 60 to stabilize the ring portion 64 against torsion (the thickness of the conductive traces 20 is greatly exaggerated in FIG. 3 ).
[0050] Referring now to FIGS. 4 and 6 , each of the downwardly extending legs 62 near its lower extent may have an outwardly extending spring biased tooth 70 which in a relaxed state projects beyond the length of the rectangular opening 60 but which may flex inward together with inward flexing of the legs 62 to allow insertion of the spring clamp 22 into the rectangular openings 60 . A lower portion of the rectangular opening 60 beneath the surface 14 expands to a greater length providing outwardly extending and downwardly facing ledges 71 . When the spring clamp 22 is fully inserted into the rectangular opening 60 , the inwardly compressed teeth 70 may relax outward to engage these ledges preventing removal of the spring clamp 22 by upward directed forces.
[0051] Referring momentarily to FIG. 5 , when the spring clamp 22 is inserted into the rectangular openings 60 and held downward by engagement of the ledges 71 and teeth 70 , the bridge 61 and ring portion 64 are flexed upward indicated by arrows 78 to provide a downward spring force 80 providing a positive engagement between the dimple 66 and the conductive trace 20 that is better resistant to vibration.
[0052] Referring again to FIGS. 4 and 6 , lower ends of the legs 62 curve upward and toward each other to provide cantilevered conductive fingers 76 that approach each other at an angle and contact along a vertical axis passing through a midpoint of the bridge 61 below the ring portion 64 . The cantilevered conductive fingers 76 may thus provide a sliding electrical engagement with the conductor 24 inserted upward through the ceramic substrate/heat sink 12 and between the endpoints of these cantilevered conductive fingers 76 . The angled approach of the cantilevered conductive fingers 76 provide for resistance against extraction of the conductor 24 whose frictional engagement with the ends of the cantilevered conductive fingers 76 tends to tighten to tighten their grip on the conductor 24 when it is withdrawn. The same flexure permits some accommodation of thermal expansion that might otherwise unduly increase the tension in the conductor 24 .
[0053] Referring to FIG. 6 , in an alternate embodiment, the LED 16 may be placed on top of one of the traces 20 and a bonding wire 82 attached between the upper surface of the LED 16 and the second trace 20 in a chip on board (COB) configuration.
[0054] Referring now to FIGS. 8 and 9 , in an alternative embodiment the conductor 24 may pass upward through the ceramic substrate/heatsink 12 with the slot 60 of FIG. 3 replaced with a vertical bore 80 sized to receive the conductor 24 and its surrounding insulation. A bared end of the conductor 24 may then pass upward through a conductive doughnut 82 joining with traces 20 to be attached thereto with solder 84 with a simple solder joint.
[0055] Various features of the invention are set forth in the following claims. It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. The invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It also being understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention.
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An assembly for high-powered LEDs provides a direct attachment of the LED to a ceramic thermal conductor/electrical insulator sealed in a housing with a compression element between a portion of the housing and ceramic heat sink to provide a predetermined range of biasing force locating the ceramic heat sink against the portion of the housing with dimensional changes in the ceramic heat sink caused by thermal expansion of the ceramic heat sink.
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BACKGROUND AND FIELD OF INVENTION
This invention relates to subterranean load-cell testing and more particularly relates to a novel and improved method and apparatus for measuring the load-bearing capacity of subterranean concrete shafts.
A previously devised method and apparatus for applying pressure and measuring upward and downward movements of the top and bottom of a load-testing device at the bottom of a concrete shaft is disclosed in my U.S. Pat. No. 4,614,110 entitled Device For Testing The Load-Bearing Capacity Of Concrete-Celled Earthen Shafts. Briefly, as set forth and described in my '110 patent, load-cell testing is carried out by placing an expansion device at the bottom of the concrete shaft and a pressurized fluid is pumped into the expansion device through a central pipe through which a telltale is inserted to measure the downward movement of the bottom of the expansion device. The telltale exits from the inside of the pressure pipe through a seal. Due to the long length of the pressure pipe, the pipe is shipped to the site in sections and must be welded in the field, and the welds must not leak under internal pressures to 8,000 psi. Once the testing has been completed, it is customary to fill the pipe and expansion device with grout by injection through the central pipe; however, it is very difficult to completely fill the pipe and expansion device without entrapping the pressurized fluid beneath the shaft.
It is therefore desirable to provide for an improved load-cell testing device of the type described which will prevent entrapment of the pressurized fluid as well as to avoid the necessity for a seal between the pipe and telltale or pressure welds in the field so as to achieve more accurate measurement of the load-bearing capacity of the shaft and assure complete filling of any voids in or beneath the shaft once the testing has been completed.
SUMMARY OF INVENTION
It is therefore an object of the present invention to provide for a novel and improved method and apparatus for testing both the end bearing and side shear resistance in a subsurface formation, particularly a subsurface formation surrounding a concrete shaft, and to be capable of filling any voids created by the test equipment in order to restore the test site to its original condition after the test is completed. The latter is of particular importance in tests performed on a working shaft in which the test equipment includes an expansion chamber at the bottom of the shaft. An important feature of the present invention is therefore to remove any entrapped fluid from the expansion chamber and completely fill it with grout so as to return the shaft to its original state.
Another object and important feature of the present invention is to provide for an improved delivery system both for pressurized fluid into an expansion chamber beneath a concrete shaft in testing the load capacity of the surrounding formation and wherein the delivery system as well as telltale measuring devices are removed from the center of the shaft and so located with respect to one another as to avoid the necessity of seals between the telltale equipment and delivery system and further eliminate the necessity of pressure welding of the delivery system in the field.
In accordance with the present invention, apparatus has been devised for measuring the load-bearing capacity of a concrete-filled subterranean shaft disposed in a hole wherein the fluid expansion member is disposed substantially flush with a bottom surface of a hole beneath the shaft, the expansion member being capable of undergoing vertically directed movement in response to fluid pressure applied thereto, the improvement comprising fluid pressure conduit means extending downwardly into the hole into communication with the expansion member for delivering fluid under pressure thereto, fluid return conduit means extending downwardly through the hole into communication with said expansion member for selectively removing fluid under pressure from the expansion member and including valve means for selectively opening and closing the fluid return conduit means, and means for delivering fluid under pressure to the fluid pressure conduit means and into the expansion chamber when the valve means is closed in order to impart upwardly and downwardly directed forces to a top and bottom of the expansion member.
Once testing is completed, grout is delivered under pressure through the fluid pressure conduit means into the expansion member until all of the pressurized fluid in the expansion member is displaced through the fluid return conduit means. To this end, the fluid pressure and fluid return conduit means are disposed in diametrically opposed relation to one another and in communication with outer peripheral portions of the expansion member. In addition, measuring means in the form of telltale rods are disposed for extension from the surface along outer peripheral portions of the hole into contact with upper and lower portions of the expansion member to measure the extent of upward and downward movement. In the alternative, a rod may be interposed between relatively moving surfaces of the expansion member and a transducer employed to sense the distance of displacement of the expansion member when the pressurized fluid is applied thereto.
The method for testing load capacity of a subsurface earth formation surrounding a concrete shaft comprises the steps of drilling a hole into the formation, placing an expansion chamber against a bottom surface of the hole with a fluid delivery conduit extending from above the formation to an outer peripheral portion of the chamber and a return conduit extending from another peripheral portion of the chamber to a location above the formation, injecting concrete into the hole to form a concrete shaft overlying the expansion chamber, pumping pressurized fluid through the delivery conduit into the expansion chamber whereby to cause the chamber to expand in upward and downward directions, and measuring the upward and downward distances of movement of the expansion chamber. The method is further characterized by cyclical loading of the expansion chamber by successively pumping fluid into the chamber and releasing pressure over a series of increments until ultimate loading or failure occurs.
The above and other objects, advantages and features of the present invention will become more readily appreciated and understood from a consideration of the following detailed description of preferred and alternate forms of invention when taken together with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section view of one preferred embodiment of the test apparatus of the present invention installed in a working shaft in a subsurface formation;
FIG. 2 is a somewhat fragmentary sectional view of the embodiment of FIG. 1 illustrating the application of pressurized fluid to an expansion chamber at the bottom of the working shaft.
FIG. 3 is another longitudinal section view of an alternate embodiment of the present invention incorporating a modified form of telltale device to that of FIGS. 1 and 2; and
FIG. 4 is a fragmentary view of the alternate form shown in FIG. 3 illustrating the expansion chamber at the bottom of the shaft in an expanded condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in more detail to the drawings, there is shown in FIGS. 1 and 2 a preferred form of load-cell testing apparatus for testing the load-bearing capacity of a subsurface formation generally designated at F in which a hole H is bored into the formation in a conventional manner and which is sized to receive a concrete shaft designated S. The shaft S is merely representative of various subsurface shafts or piers utilized, for example, as a foundation for bridges, buildings and the like and which must meet certain federal and state building codes for load-bearing capacities of subsurface structures. In order to carry out load-cell testing of the formation, the hole H is prepared such that the bottom is clean and flat so as to accommodate an expansion member in the form of a hydraulic jack 11, the latter being comprised of a cylindrical piston 12 disposed in sealed relation to a cylinder 13. The piston 12 includes a base plate 14 upon which is mounted a solid cylindrical body 15 of a diameter or slightly less than that of the base plate 14. The base plate 14 in turn is mounted on a larger platform or plate 16 which rests on the bottom of the hole and is sized to closely correspond to the diameter of the hole H. The cylinder 13 is in the form of an inverted end cap having a circular end plate 17 at its upper end, an outer surrounding side wall 18, and a top plate 19 is surmounted on the upper end plate 17. An annular seal 20 is interposed between the side wall 18 and body 15 so as to define a pressure chamber 22 therebetween.
In order to deliver hydraulic fluid under pressure into the chamber 22, a delivery hose 24 extends downwardly from a source of fluid under pressure at the surface and vertically along the outer peripheral edge of the hole H into communication with a hose fitting 26 which extends through the end plate 17 of the cylinder 13 and a recess 28 in the top plate 19. A suitable pressure gauge 29 is provided at the surface, and any suitable form of hydraulic pump P may serve as the pressurized fluid source. A return hose 30 extends upwardly from a second hose fitting 32 which extends through the end plate 17 from communication with the pressure chamber 22 and upwardly into a recess 34 which is preferably disposed in diametrically opposed relation to the hose fitting 26 in the top plate 19. Although the delivery and return hoses 24 and 30 are shown in diametrically opposed relation to one another extending vertically along the outer peripheral surface portions of the hole H it will be apparent that the hoses need not be located precisely in diametrically opposed relation to one another but merely disposed in circumferentially spaced relation to one another and both located toward the outer periphery of the pressure chamber 22 as well as the outer periphery of the hole H. The return hose 30 includes a suitable valve 36 at the surface.
In order to measure downward displacement of the expansion chamber 22, telltale rods 40 are slidable through sleeves 42 which are fixed in diametrically opposed relation to one another on the platform 16. Upward slidable movement of each rod 40 through the sleeve 42 in response to downward movement is measured by a digital displacement indicator 44 which is attached to a reference beam 45 extending horizontally across the shaft at the surface. One suitable form of indicator is Model No. DPX 1264, manufactured and sold by Chicago Dial Indicator Company of Des Plaines, Ill. Similarly, the upward movement of the top plate 19 is measured by telltale rods 46 having indicators 47 corresponding to those for the telltale rods 40 at the surface and which are attached to the common reference beam 45. Still another telltale rod 48 extends downwardly from the reference beam 45 into the concrete shaft S in order to measure the upward movement of the top of the concrete and includes an indicator 49 affixed to the reference beam 45.
From the foregoing, once the testing apparatus 10 is installed in an empty hole H, the hole H then can be partially or fully filled with concrete to the desired level for testing, and the reference beam 45 is provided with downwardly extending posts 50 which are driven into the formation at the surface surrounding the hole H. Water, oil or other pressurized fluid enters the pressure chamber 22 via the hose 24, the valve 36 on the return hose 30 being opened and the pressurized fluid being flushed through the chamber 22 in order to purge the system of air. Once the air is expelled, the valve 36 is closed and pressure is applied to the pressure chamber 22, the applied pressure being measured by the pressure gauge 29. The introduction of fluid under pressure into the chamber 22 causes equal upward and downward forces to be applied to the top of the cylinder 13 and upper end of the piston 12, respectively. The downward force is resisted by the subsurface formation at the bottom of the hole, hereinafter referred to as "end bearing". The upward force is resisted by the shear resistance between the concrete in the shaft and the subsurface formation along the interface between the concrete and peripheral surface of the hole, hereinafter referred to as "side shear". As the load increases, downward movement occurs due to the end bearing yielding, and upward movement of the concrete shaft occurs due to the side shear yielding along the interface. By measuring the upward and downward movements separately, separate upward and downward load-deflection curves can be drawn or recorded. Ultimate load or failure will occur either in side shear or end bearing when no further increase of load occurs with continued deflection. Again, the downward movement is measured by the telltale indicators 44, and the upward movement of the top plate 19 is measured by the telltale indicators 47. The difference in the average upward movement of the top plate 19 as measured by the indicators 47 and the upward movement of the top of the concrete as measured by the telltale indicators 49 is the elastic compression of the concrete shaft S above the top plate of the device. When the testing is completed and the concrete shaft S is to be used as part of the foundation for the finished structure, the valve 36 is opened and a high strength fluid grout, preferably consisting of cement, sand and water, is pumped into the pressure chamber 22 through the delivery hose 24 and out through the return hose 30 until all of the pressurized fluid is displaced and expelled from the system. The valve 36 is then closed and the grout allowed to harden and reach its designed strength. In certain applications it may be desirable to maintain a prestress in the concrete shaft S by holding a predetermined load to be maintained by the grout. In such case, the valve 36 is closed and the grout is held at a predetermined pressure level until it has reached its designed strength.
A modified form of load cell testing apparatus 10' is illustrated in FIGS. 3 and 4 wherein like parts are correspondingly enumerated to those of FIGS. 1 and 2. Accordingly, the pressure chamber 22' corresponds to that of FIGS. 1 and 2 but eliminates the bottom platform 16 and top plate 19, the hoses 24' and 30' communicating directly with the pressure chamber 22' through the end plate 17' of the cylinder 13'. The principal modification in the form of FIGS. 3 and 4 resides in the utilization of an electronic sensing member having a rod 54 affixed to an upper plate 56 of the piston 12' and being slidable through a sleeve 58 in the end plate 17'. A linear variable differential transducer 60 is mounted in the sleeve 56 with a connecting wire 62 extending upwardly through the delivery hose 24' from the sleeve 56 and connected to a suitable recorder R at the surface. Displacement of the cylinder 13' away from the piston 12' when pressurized fluid is pumped into the chamber 22' will be sensed by the transducer 62 to provide a measurement of the change of distance between the end plate 17' and the upper plate 56 of the piston 12'. Displacement of the concrete shaft S' in response to applied pressure is once again sensed by a telltale indicator 49' connected to the rod 48' at the surface. Thus, FIG. 3 illustrates the testing device in its contracted position prior to introduction of pressure, and FIG. 4 illustrates the apparatus 10' after application of pressure and expansion of the cylinder 13' away from the piston 12'.
Customarily, the pressure chamber 22' will be capable of undergoing a displacement on the order of 6 inches depending upon the characteristics of the subsurface formation; and, by subtracting the upward movement of the shaft S' from the change in distance between the top and bottom of the cylinder 13' and piston 12' respectively, the downward movement of the
This bottom of the piston 12' can be determined assumes that the concrete in the shaft is incompressible in comparison with the movements which occur due to side shear and end bearing. Although small, a reasonable estimate of the compression of the concrete in the shaft above the load cell can be determined by calculating the compression and knowing the force applied and modules of elasticity of the concrete or reinforced concrete, as the case may be. For the purpose of illustration but not limitation, one suitable form of commercially available transducer 60 is a Model No. 4450 Geokon Vibrating Wire Displacement Wire Transducer manufactured and sold by Geokon, Inc. of Lebanon, N.H. Further, it will be evident that the movements of the telltales of FIGS. 1 and 2 or FIGS. 3 and 4 can be sensed and converted into digital readings, from which the load-deflection curves can be plotted automatically.
Both in the preferred and modified forms of invention of FIGS. 1 to 4, the applied pressure may be gradually increased up to the maximum permissible pressure until ultimate load or failure occurs either in side shear or end bearing such that there is no further increase in load with continued deflection or expansion. An additional feature resides in the ability to cyclically load the test cell; or, in other words to load at any rate up to the capacity rate of the system either until the ultimate loading occurs, or by applying load cycles in preset load and time increments until the ultimate load is reached. Cyclical loading in the manner described may be applicable for testing any drilled shaft foundation which is subjected to cyclic load while in service including earthquake loading.
For the purpose of illustration, cyclic loading may be employed in a series of increments in which, for example, pressurized fluid is delivered via hose 24 or 24' into the expansion chamber 22 or 22' over an extremely short time interval on the order of several seconds for each increment. The valve 36 or 36' on the return conduit 30 or 30' is then instantaneously opened to cause the pressure to be released to zero or a minimum load then immediately closed and the next incremental pressure or loading applied by the pump to a higher pressure level, followed by immediately releasing to zero, and successively pumping and releasing in a repetitive manner until ultimate loading or failure occurs. After each cycle or increment there is some residual settlement of the concrete shaft and expansion chamber when the load is released to zero; and, after each cycle, the settlement increases until at some increment the settlement will increase without any or very little increase in load.
The type of cyclic loading described is used when the expected load on the shaft due to the supporting structure undergoes large fluctuations. In testing, most desirably the loads are applied rapidly at estimated speeds of only a few seconds for each load cycle and such testing may therefore be automated utilizing any suitable form of electronic sensing control circuitry or computer programming to successively activate the pump for the delivery conduit 24 or 24' and the value 36 or 36' for the return conduit 30 or 30'.
It is therefore to be understood that while preferred and alternate forms of invention have been herein set forth and described, various modifications and changes may be made therein without departing from the spirit and scope of the invention as defined by the following claims and reasonable equivalents thereof.
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A method and apparatus for testing the load-bearing capacity of a subterranean formation surrounding a concrete shaft and is made up of an expansion chamber at the bottom of the hole containing the shaft and fluid pressure and return lines which extend downwardly into communication with spaced outer peripheral portions of the expansion chamber so that when fluid is pumped into the chamber any entrapped air can be removed through the return line, and when grout is subsequently pumped into the chamber any fluid can be displaced through the return line. Telltale measuring rods extend downwardly into contact with spaced outer peripheral portions of the expansion chamber to measure displacement of the chamber when pressurized fluid is delivered into the chamber. The method of testing may be applied also in cyclical loading of the formation beneath the shaft to simulate a support structure which undergoes large fluctuations in loading, for example, of the type induced by an earthquake.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/351,252 filed Jun. 3, 2010, U.S. Provisional Application Ser. No. 61/397,780 filed Jun. 15, 2010, and U.S. Provisional Application Ser. No. 61/456,774 filed Nov. 12, 2010 which are incorporated by reference herein in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to data mining and information retrieval and more specifically semantic interpretation of keywords used data mining and information retrieval.
BACKGROUND
[0003] The bag of words (BOW) model has been shown to be very effective in diverse areas which span a large spectrum from traditional text-based applications to web and social media. While there have been a number of models in information retrieval systems using the bag of words, including boolean, probability and fuzzy ones, the word-based vector model is the most commonly used in the literature. In the word-based vector model, given a dictionary, U, with u distinct words, a document is represented as u-dimensional vector {right arrow over (d)}, where only those positions in the vector that correspond to the document words are set to >0 and all others are set to 0, which results in a collection of the extremely sparse vectors in a high dimension space.
[0004] Although the BOW-based vector model is the most popular scheme, it has limitations: these include sparsity of vectors and lacking semantic relationship between words. One way to overcome these limitations is to analyze the keywords of the documents in the corpus to extract latent concepts that are dominant in the corpus, and models documents in the resulting latent concept-space. While these techniques have produced impressive results in text-based application domains, they still have a limitation in that the resulting latent concepts are different from human-organized knowledge, and thus they cannot be interpreted by human knowledge.
[0005] A possible solution to resolve this difficulty is to enrich the individual documents with the background knowledge obtained from existing human-contributed knowledge databases; i.e., Wikipedia, WordNet, and Open Directory Project. For example, Wikipedia is one of the largest free encyclopedias on the Web, containing more than 4 million articles in the English version. Each article in Wikipedia describes a concept (topic), and each concept belongs to at least one category. Wikipedia uses redirect pages, which redirects a concept to another concept, for synonymous ones. On the other hand, if a concept is polysemous, Wikipedia displays possible meanings of polysemous concepts in disambiguation pages.
[0006] Due to its comprehensiveness and expertise, Wikipedia has been applied to diverse applications, such as clustering, classification, word disambiguation, user profile creation, link analysis, and topic detection, where it is used as a semantic interpreter which re-interprets (or enriches) original documents based on the concepts of Wikipedia. As shown in FIG. 5 , such semantic re-interpretation 500 equals or corresponds to a mapping of original documents from the keyword-space 510 into the concept-space 520 . Generally, the mapping between the original dictionary and the concept is performed by (a) matching concepts to keywords and (b) replacing the keywords with these matched concepts. In the literature, this process is commonly defined as the matrix multiplication between the original keyword matrix and the keyword-concept matrix ( FIG. 5 ). Such a Wikipeda-based semantic re-interpretation has the potential to ensure that keywords mapped into the Wikipedia concept-space are semantically informed, significantly improving the effectiveness on various tasks, including text categorization and clustering.
[0007] The main obstacle in leveraging a source such as the Wikipedia as a semantic interpreter stems from efficiency concerns. Considering the sheer size of Wikipedia articles (more than 4 million concepts), reinterpreting original documents based on all possible concepts of Wikipedia can be prohibitively expensive. Therefore, it is essential that the techniques used for such a semantic re-interpretation should be fast.
[0008] More importantly, enriching original documents with all possible Wikipedia concepts, for example, imposes an additional overhead in the application level, since enriched-documents will be represented in the augmented concept-space that corresponds to a very high dimension. Most applications do not require documents to be represented with all possible Wikipedia concepts, since they are not equally important to the given document. Indeed, insignificant concepts tend to be noisy. Thus, there is a need to efficiently find the best k concepts in Wikipedia that match a given original document, and semantically reinterpret it based on such k concepts.
SUMMARY
[0009] Given a keyword matrix representing the keyword collection, efficiently identifying the best-k results that match a given keyword query is not trivial. Firstly, the size of keyword matrix is huge. Secondly, the sparsity of keyword matrix limits us to apply the most well-known top-k processing methods to our problem. Thus, the goal is to develop efficient mechanisms to compute the approximate top-k keywords that are most relevant to the given document query. In particular, the SparseTopk algorithm is presented that can effectively estimate the scores of unseen objects in the presence of a user (application) provided acceptable precision rate and computes the approximate top-k results based on these expected scores.
[0010] In accordance with one embodiment, a method is provided for semantic interpretation of keywords. The method includes the steps of obtaining one or more keywords for semantic interpretation; computing top-k concepts in a knowledge database for the one or more keywords; and mapping the one or keywords into a concept space using the top-k concepts.
[0011] In accordance with another embodiment, a system is provided for performing automatic image discovery for displayed content. The system includes a topic detection module, a keyword extraction module, an image discovery module, and a controller. The topic detection module is configured to detect a topic of the content being displayed. The keyword extraction module is configured to extract query terms from the topic of the content being displayed. The image discovery module is configured to discover images based on query terms; and the controller is configured to control the topic detection module, keyword extraction module, and image discovery module.
[0012] These and other aspects, features and advantages of the present principles will become apparent from the following detailed description of exemplary embodiments, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present principles may be better understood in accordance with the following exemplary figures, in which:
[0014] FIG. 1 is a system diagram outlining the delivery of video and audio content to the home in accordance with one embodiment.
[0015] FIG. 2 is system diagram showing further detail of a representative set top box receiver in accordance with one embodiment.
[0016] FIG. 3 is a diagram showing a process performed at the set top box receiver in accordance with one embodiment.
[0017] FIG. 4 is a flow diagram showing the process of semantic interpretation in accordance with one embodiment.
[0018] FIG. 5 is a diagram showing how a semantic interpreter maps keywords from the keyword space to the concept space in accordance with one embodiment.
[0019] FIG. 6 is the general framework of a semantic interpreter which relies on ranked processing schemes in accordance with one embodiment.
[0020] FIG. 7 is an example of pseudo-code for computing the approximate top-k concepts in accordance with one embodiment.
[0021] FIG. 8 is an example of pseudo-code for mapping the keywords from the keyword space to the concept space.
DETAILED DESCRIPTION
[0022] The present principles are directed to content search and more specifically semantic interpretation of keywords used for searching using a Top-k technique.
[0023] It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the present invention and are included within its spirit and scope.
[0024] All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the present invention and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions.
[0025] Moreover, all statements herein reciting principles, aspects, and embodiments of the present invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future, i.e., any elements developed that perform the same function, regardless of structure.
[0026] Thus, for example, it will be appreciated by those skilled in the art that the block diagrams presented herein represent conceptual views of illustrative circuitry embodying the present invention. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudocode, and the like represent various processes which may be substantially represented in computer readable media and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.
[0027] The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” or “controller” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (“DSP”) hardware, read-only memory (“ROM”) for storing software, random access memory (“RAM”), and non-volatile storage.
[0028] Other hardware, conventional and/or custom, may also be included. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the implementer as more specifically understood from the context.
[0029] In the claims hereof, any element expressed as a means for performing a specified function is intended to encompass any way of performing that function including, for example, a) a combination of circuit elements that performs that function or b) software in any form, including, therefore, firmware, microcode or the like, combined with appropriate circuitry for executing that software to perform the function. The present invention as defined by such claims resides in the fact that the functionalities provided by the various recited means are combined and brought together in the manner which the claims call for. It is thus regarded that any means that can provide those functionalities are equivalent to those shown herein.
[0030] Reference in the specification to “one embodiment” or “an embodiment” of the present invention, as well as other variations thereof, means that a particular feature, structure, characteristic, and so forth described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrase “in one embodiment” or “in an embodiment”, as well any other variations, appearing in various places throughout the specification are not necessarily all referring to the same embodiment.
[0031] Turning now to FIG. 1 , a block diagram of an embodiment of a system 100 for delivering content to a home or end user is shown. The content originates from a content source 102 , such as a movie studio or production house. The content may be supplied in at least one of two forms. One form may be a broadcast form of content. The broadcast content is provided to the broadcast affiliate manager 104 , which is typically a national broadcast service, such as the American Broadcasting Company (ABC), National Broadcasting Company (NBC), Columbia Broadcasting System (CBS), etc. The broadcast affiliate manager may collect and store the content, and may schedule delivery of the content over a deliver network, shown as delivery network 1 ( 106 ). Delivery network 1 ( 106 ) may include satellite link transmission from a national center to one or more regional or local centers. Delivery network 1 ( 106 ) may also include local content delivery using local delivery systems such as over the air broadcast, satellite broadcast, or cable broadcast. The locally delivered content is provided to a receiving device 108 in a user's home, where the content will subsequently be searched by the user. It is to be appreciated that the receiving device 108 can take many forms and may be embodied as a set top box/digital video recorder (DVR), a gateway, a modem, etc. Further, the receiving device 108 may act as entry point, or gateway, for a home network system that includes additional devices configured as either client or peer devices in the home network.
[0032] A second form of content is referred to as special content. Special content may include content delivered as premium viewing, pay-per-view, or other content otherwise not provided to the broadcast affiliate manager, e.g., movies, video games or other video elements. In many cases, the special content may be content requested by the user. The special content may be delivered to a content manager 110 . The content manager 110 may be a service provider, such as an Internet website, affiliated, for instance, with a content provider, broadcast service, or delivery network service. The content manager 110 may also incorporate Internet content into the delivery system. The content manager 110 may deliver the content to the user's receiving device 108 over a separate delivery network, delivery network 2 ( 112 ). Delivery network 2 ( 112 ) may include high-speed broadband Internet type communications systems. It is important to note that the content from the broadcast affiliate manager 104 may also be delivered using all or parts of delivery network 2 ( 112 ) and content from the content manager 110 may be delivered using all or parts of delivery network 1 ( 106 ). In addition, the user may also obtain content directly from the Internet via delivery network 2 ( 112 ) without necessarily having the content managed by the content manager 110 .
[0033] Several adaptations for utilizing the separately delivered content may be possible. In one possible approach, the special content is provided as an augmentation to the broadcast content, providing alternative displays, purchase and merchandising options, enhancement material, etc. In another embodiment, the special content may completely replace some programming content provided as broadcast content. Finally, the special content may be completely separate from the broadcast content, and may simply be a media alternative that the user may choose to utilize. For instance, the special content may be a library of movies that are not yet available as broadcast content.
[0034] The receiving device 108 may receive different types of content from one or both of delivery network 1 and delivery network 2 . The receiving device 108 processes the content, and provides a separation of the content based on user preferences and commands. The receiving device 108 may also include a storage device, such as a hard drive or optical disk drive, for recording and playing back audio and video content. Further details of the operation of the receiving device 108 and features associated with playing back stored content will be described below in relation to FIG. 2 . The processed content is provided to a primary display device 114 . The primary display device 114 may be a conventional 2-D type display or may alternatively be an advanced 3-D display.
[0035] The receiving device 108 may also be interfaced to a second screen such as a second screen control device, for example, a touch screen control device 116 . The second screen control device 116 may be adapted to provide user control for the receiving device 108 and/or the display device 114 . The second screen device 116 may also be capable of displaying video content. The video content may be graphics entries, such as user interface entries, or may be a portion of the video content that is delivered to the display device 114 . The second screen control device 116 may interface to receiving device 108 using any well known signal transmission system, such as infra-red (IR) or radio frequency (RF) communications and may include standard protocols such as infra-red data association (IRDA) standard, Wi-Fi, Bluetooth and the like, or any other proprietary protocols. Operations of touch screen control device 116 will be described in further detail below.
[0036] In the example of FIG. 1 , the system 100 also includes a back end server 118 and a usage database 120 . The back end server 118 includes a personalization engine that analyzes the usage habits of a user and makes recommendations based on those usage habits. The usage database 120 is where the usage habits for a user are stored. In some cases, the usage database 120 may be part of the back end server 118 a . In the present example, the back end server 118 (as well as the usage database 120 ) is connected to the system the system 100 and accessed through the delivery network 2 ( 112 ).
[0037] Turning now to FIG. 2 , a block diagram of an embodiment of a receiving device 200 is shown. Receiving device 200 may operate similar to the receiving device described in FIG. 1 and may be included as part of a gateway device, modem, set top box, or other similar communications device. The device 200 shown may also be incorporated into other systems including an audio device or a display device. In either case, several components necessary for complete operation of the system are not shown in the interest of conciseness, as they are well known to those skilled in the art.
[0038] In the device 200 shown in FIG. 2 , the content is received by an input signal receiver 202 . The input signal receiver 202 may be one of several known receiver circuits used for receiving, demodulating, and decoding signals provided over one of the several possible networks including over the air, cable, satellite, Ethernet, fiber and phone line networks. The desired input signal may be selected and retrieved by the input signal receiver 202 based on user input provided through a control interface 222 . Control interface 222 may include an interface for a touch screen device. Touch panel interface 222 may also be adapted to interface to a cellular phone, a tablet, a mouse, a high end remote or the like.
[0039] The decoded output signal is provided to an input stream processor 204 . The input stream processor 204 performs the final signal selection and processing, and includes separation of video content from audio content for the content stream. The audio content is provided to an audio processor 206 for conversion from the received format, such as compressed digital signal, to an analog waveform signal. The analog waveform signal is provided to an audio interface 208 and further to the display device or audio amplifier. Alternatively, the audio interface 208 may provide a digital signal to an audio output device or display device using a High-Definition Multimedia Interface (HDMI) cable or alternate audio interface such as via a Sony/Philips Digital Interconnect Format (SPDIF). The audio interface may also include amplifiers for driving one more sets of speakers. The audio processor 206 also performs any necessary conversion for the storage of the audio signals.
[0040] The video output from the input stream processor 204 is provided to a video processor 210 . The video signal may be one of several formats. The video processor 210 provides, as necessary, a conversion of the video content, based on the input signal format. The video processor 210 also performs any necessary conversion for the storage of the video signals.
[0041] A storage device 212 stores audio and video content received at the input. The storage device 212 allows later retrieval and playback of the content under the control of a controller 214 and also based on commands, e.g., navigation instructions such as fast-forward (FF) and rewind (Rew), received from a user interface 216 and/or control interface 222 . The storage device 212 may be a hard disk drive, one or more large capacity integrated electronic memories, such as static RAM (SRAM), or dynamic RAM (DRAM), or may be an interchangeable optical disk storage system such as a compact disk (CD) drive or digital video disk (DVD) drive.
[0042] The converted video signal, from the video processor 210 , either originating from the input or from the storage device 212 , is provided to the display interface 218 . The display interface 218 further provides the display signal to a display device of the type described above. The display interface 218 may be an analog signal interface such as red-green-blue (RGB) or may be a digital interface such as HDMI. It is to be appreciated that the display interface 218 will generate the various screens for presenting the search results in a three dimensional gird as will be described in more detail below.
[0043] The controller 214 is interconnected via a bus to several of the components of the device 200 , including the input stream processor 202 , audio processor 206 , video processor 210 , storage device 212 , and a user interface 216 . The controller 214 manages the conversion process for converting the input stream signal into a signal for storage on the storage device or for display. The controller 214 also manages the retrieval and playback of stored content. Furthermore, as will be described below, the controller 214 performs searching of content and the creation and adjusting of the gird display representing the content, either stored or to be delivered via the delivery networks, described above.
[0044] The controller 214 is further coupled to control memory 220 (e.g., volatile or non-volatile memory, including RAM, SRAM, DRAM, ROM, programmable ROM (PROM), flash memory, electronically programmable ROM (EPROM) , electronically erasable programmable ROM (EEPROM), etc.) for storing information and instruction code for controller 214 . Control memory 220 may store instructions for controller 214 . Control memory may also store a database of elements, such as graphic elements containing content. The database may be stored as a pattern of graphic elements. Alternatively, the memory may store the graphic elements in identified or grouped memory locations and use an access or location table to identify the memory locations for the various portions of information related to the graphic elements. Additional details related to the storage of the graphic elements will be described below. Further, the implementation of the control memory 220 may include several possible embodiments, such as a single memory device or, alternatively, more than one memory circuit communicatively connected or coupled together to form a shared or common memory. Still further, the memory may be included with other circuitry, such as portions of bus communications circuitry, in a larger circuit.
[0045] The user interface process of the present disclosure employs an input device that can be used to express functions, such as fast forward, rewind, etc. To allow for this, a second screen control device such as a touch panel device may be interfaced via the user interface 216 and/or control interface 222 of the receiving device 200 .
[0046] FIG. 3 depicts one possible embodiment of the process 300 involved in performing semantic interpretation in Set Top Box (STB) 310 such as receiving device 106 , 200 discuss above in regard to FIGS. 1 and 2 . Here STB 310 receives content 305 from a content source 102 . The content 305 is then processed in three parts: 1) keyword collection 320 , 2) concept collection 340 , 3) concept processing 360 . In the keyword collection 320 , A Close Caption Extractor 325 is used to receive, capture, and otherwise extract the close captioning data provided as part of the content 305 . A Sentence Segmenter 330 is then used to identify sentence structures in the close captioning data to look for candidate phrases and keywords such as the subject or object of sentences as well as whole phrases. For many sentences in closed captioning, the subject phrases are very important. As such, a dependency parser can be used to find the head of a sentence and if the head of the sentence is also a candidate phrase, the head of the sentence can be given a higher priority. The candidate keywords are then used to find relevant concepts in concept collection 340 . This is also where a Semantic Interpreter 350 is used to map the candidate keywords into concepts. The concepts can then be groupe together by the concept accumulator 340 . The resulting accumulated concepts can then be processed 360 . This can include ranking 365 and other functionality such as creating a user profile 370 .
[0047] For example, close captioning of segments can be used to create a TV watching profile for users, so that content can be personalized, thereby improving the quality of recommendations given to the user. There are many other applications of creating an accurate and informative user profile, such as being able to match advertisements or to suggest friends that have similar interests. A key problem faced by current systems for creating profiles from a user's TV watching habits is the sparsity and lack of accurate data. In order to mitigate this issue, close captioning segments corresponding to the TV program segments watched can be captured, along with other metadata such as the time of viewing and the EPG information of the program. By capturing the close captioning, it is possible to understand what the user's interests are and provides a basis to give content based recommendations. Furthermore, when the captured close captioning is mapped to concept space using the semantic interpreter, the resulting profile is more intuitive to understand, and to exploit. As an extra benefit, the amount of data needed to be stored is reduced as the entire close captioning segments are not stored. Only the top-k concepts that the close captioning segment represents are stored.
[0048] In another example, concepts mapped by the semantic interpreter can be used to segment videos, both online (for e.g. live/broadcast), and offline (for e.g. DVRed) based on close captioning data. Each segment should contain a set of concepts so that it is one coherent unit (e.g., a segment on Tiger Woods in the evening news). Once the video is segmented, the corresponding close captioning segment can be mapped to the concept space and the video annotated with the resulting top-k concepts. An application of this will be to let people share these mini clips with friends or save them to DVR or simply tag it as interesting. This is useful as the users are not interested in an entire video or the entire video might be too big to share or might have copyright issues. Modern DVRs already record the program being watched in order to provide live pause/rewind functions. This can be further augmented to trigger the segmentation and concept-mapping algorithms so that the resulting segments can be tagged and/or saved and/or shared along with brief time intervals (+/- t seconds) before and after the detected segment.
[0049] In another example, these techniques can be used to improve searches. Currently, users need to search for information using exact keywords in order to find programs of interest. While this is useful if the user knows exactly what he or she is looking for, searching exact keywords impedes discovery of newer and more exciting content that might be of interest to the user. The semantic interpreter can be used to solve this problem. The concept space can be derived from the Wikipedia as it can be deemed for practical purposes to represents the entire human knowledge. Any document represented in this space can hence be queried using the same concepts. For example, the user should be able to use high level knowledge such as “Ponzi Scheme” or “Supply Chain” and discover media that is most relevant to that concept. This discovery will be possible even if the corresponding media has no keywords that exactly match “Ponzi Scheme” or “Supply Chain”. Furthermore, by setting up standing filters, any incoming media can be mapped to the concept space and if the concepts match the standing filter, then such media can be tagged for further action by the system. When programs that match the users filter rule is broadcast the user is notified and choose to save, browse related, share or view them.
[0050] While in the example of FIG. 3 , the process is performed in STB 310 , it should be understood the same process can also be performed at the content source 102 or service provider 104 , 110 . In some instances, the parts can be split among different devices or locations as necessary or desired. Indeed, in many instances the semantic interpretation is performed at a remote server and the resulting concepts are provided back to the STB 310 , content source 102 , or service provider 104 , 110 for further processing.
[0051] In the case of processing at the content source 102 , when content is created, the corresponding close captioning or subtitle data is mapped to the concept space. The inferred concepts are then embedded into the media multiplex as a separate stream (for e.g. using the MPEG-7 standard). The advantage is that the process needs to be performed only once per media file instead of multiple times. The disadvantage is that standards need to be developed for embedding, further processing and consumption of this meta-data.
[0052] In the case of processing at the service provider 104 or 110 , the processing occurs when content is transmitted via the service provider's network or in the cloud. For example, the service provider can process all incoming channels using a Semantic Interpreter and embed the metadata in a suitable fashion (MPEG-7, proprietary or using web based technologies). The service provider need not resort to standard schemes, as long as their STB can interpret and further process this metadata. The big advantage of this approach is that no elaborate standards need to be developed; also, these schemes can be used to differentiate different service providers.
[0053] Referring now to FIG. 4 , a flow diagram 400 is depicted showing one embodiment of the process involved in performing Semantic Interpretation using top K concepts. First, one or more keywords are obtained for semantic interpretation (step 410 ). The one or more keywords are then used to compute top-k concepts in a knowledge database (step 420 ). The keywords can then be mapped into a concept space using the top-k concepts (step 430 ).
[0054] The one or more keyword can be obtained in any number of ways. Keywords may be obtained using keyword extraction involving close caption data as described above in reference to FIG. 3 . In other embodiments keywords can be extracted from data related to a piece of content such a summary, program description, abstract, synopsis, etc. In still other embodiments a user can provide search terms. In the description of the process below the keywords are provided as part of a document.
[0055] The step of computing the top-k concepts (Step 420 ) and mapping to a concept space (Step 430 ) is described below in conjunction FIGS. 5-8 with the discussion of the SparseTopk algorithm.
Problem Definition
[0056] In this section, the problem is formally defined and the notation used to develop and describe the algorithms is introduced.
[0000] Semantic Reinterpretation with the All Possible Wikipedia Concepts
[0057] Let u be a dictionary with u distinct words. The concepts in Wikipedia, for example, are represented in the form of a u×m c-concept matrix, C ( 530 ) where m is the number of concepts that corresponds to articles of Wikipedia and u is the number of distinct keywords in the dictionary. Let C i,r denote the weight of the i-th keyword t i , in the r-th concept, c r . Let C−, r =[w 1,r , w 2,r , . . . , w u,r ] T be the r-th concept vector. Without loss of generality, it is assumed that each concept-vector, C− r , is normalized into a unit length.
[0058] Given a dictionary u, a document, d, is represented as a l-dimensional vector, {right arrow over (d)}=[w 1 , w 2 , . . . , w u ] ( 515 ).
[0059] Given a keyword-concept matrix, C( 530 ), and a document vector, c I, a semantically re-interpreted (enriched) document vector with all possible Wikipedia concepts, {right arrow over (d)}=[w′ 1 , w′ 2 , . . . , w′ m ] ( 525 ), is defined as
[0000] {right arrow over (d)}′={right arrow over (d)}C.
[0060] By definition of matrix multiplication, the contribution of the concept c r in the vector {right arrow over (d)}′ is computed as follows:
[0000]
w
r
′
=
∑
1
≤
i
≤
u
w
i
×
C
i
,
r
=
∑
∀
w
i
≠
0
w
i
×
C
i
,
r
.
[0000] Semantic Reinterpretation with the Top-k Wikipedia Concepts
[0061] As mentioned in the introduction, computing {right arrow over (d)}′ all possible Wikipedia concepts may be prohibitively expensive. Thus, the goal is to reinterpret a document with the best k concepts in Wikipedia that are relevant to it.
[0062] Given a re-interpreted document {right arrow over (d)}′=[w′ 1 ; w′ 2 , . . . , w′ m ], let S k be a set of k concepts, such that the following holds:
[0000] ∀ c r ∈S k , c p ∉S k w′ r ≧w′ p .
[0063] In other words, S k contains k concepts whose contributions to {right arrow over (d)}′ are greater than or equal to the others. Then, a semantic re-interpretation of {right arrow over (d)} based on the top-k concepts in Wikipedia that match it is defined as {right arrow over (d)}=[w′ 1 , w′ 2 , . . , w′ m ] where
[0000]
if
c
r
∈
S
k
,
w
r
′
=
∑
1
≤
i
≤
u
w
i
×
C
i
,
r
=
∑
∀
w
i
≠
0
w
i
×
C
i
,
r
otherwise
,
w
r
′
=
0.
[0000] Problem Definition: Semantic Reinterpretation with the Approximate Top-k Wikipedia Concepts
[0064] Exactly computing the best k concepts that are relevant to a given document often requires scanning an entire keyword-concept matrix, which is very expensive. Thus, in order to achieve further efficiency gains, S k is relaxed as follows: given a document {right arrow over (d)}, let S k,α be a set of k concepts such that at least αk answers in S k,α belong to S k , where 0≦α≦1. Then, the objective is defined as follows:
[0000] Problem 1 (Semantic re-interpretation with S k,α ) Given a keyword-concept matrix, C, a document vector, {right arrow over (d)}, and the corresponding approximate best k concepts, S k,α , a semantic re-interpretation of {right arrow over (d)} based on the approximate top-k concepts in Wikipedia that match it is defined as {right arrow over (d)}=[w′ 1 , w′ 2 , . . . , w′ m ] where
[0000]
if
c
r
∈
S
k
,
α
,
w
r
′
≈
∑
1
≤
i
≤
u
w
i
×
C
i
,
r
=
∑
∀
w
i
≠
0
w
i
×
C
i
,
r
otherwise
,
w
r
′
=
0.
[0065] In other words, the original document, d, is approximately mapped from the word-space 510 into the concept-space 520 which consists of the approximate k concepts in Wikipedia that best match a document d. Thus, the key challenge to this problem is how to efficiently identify such approximate top-k concepts, S k,α . To address this problem, a novel ranked processing algorithm is presented to efficiently compute S k,α for a given document.
Naive Solutions to S k
[0066] In this section, naive schemes (i.e. impractical solutions) are first described for exactly computing the top-k concepts, S k , of a given document.
Scanning the Entire Data
[0067] One obvious solution to this problem is to scan the entire u×m. keyword-concept matrix, C 530 , multiply the document vector, cl, with each concept vector, C=r, sort the resulting scores, w′ r (where 1≦r≦m), in descending order, and choose only the k -best solutions. A more promising solution to this problem is to leverage an inverted index, commonly used in IR systems, which enables to scan only those entries whose corresponding values in the keyword-concept matrix are greater than 0. Both schemes would be quite expensive, because they waste most of resources in processing unpromising data that will not belong to the best k results.
Threshold-Based Ranked Processing Scheme
[0068] There have been a large number of proposals for ranked or top-k processing. As stated above, the threshold-based algorithms, such as Threshold Algorithm (TA), Fagin's Algorithm (FA), and No Repeating Algorithm (NRA) are the most well-known methods. These algorithms assume that given sorted-lists, each object has a single score in each list and an aggregation function, which combines independent object's scores in each list, is monotone such as min, max, (weight) sum and product. These monotone scoring functions guarantee that a candidate dominating the other one in its sub-scores will have a combined score better than the other one, which enables early stopping during the top-k computation, to avoid scanning all the lists. Generally, TA (and FA) algorithms require two access methods: random-access and sorted-access. However, supporting random-access to a high-dimensional data, such as document-term matrix, would be prohibitively expensive. Therefore, NRA is employed as a base framework, since it requires only a sorted-access method, and thus is suitable for high-dimensional data, such as a concept matrix C.
Sorted Inverted Lists for the Concept Matrix
[0069] To support sorted accesses to auxm keyword-concept matrix, C 530 , an inverted index 610 that contains u lists is created ( FIG. 6 ). For each keyword t i , the corresponding list T i,r contains a set of c r , C i,r s, where is the weight of the keyword, l i , in Wikipedia concept c r . As shown in FIG. 6 , each inverted list maintains only concepts whose weights are greater than 0. This inverted list is created in decreasing value on weights to support sorted accesses.
NRA-Based Scheme for Computing S k
[0070] From the definition of given above, it is clear that the score function is monotone in the u independent lists since it is defined as a weight sum. Given a document {right arrow over (d)}=[w 1 , w 2 , . . . , w u ], NRA visits the input lists in a round-robin manner and updates a threshold vector t{right arrow over (h)}=[τ 1 , τ 2 , . . , τ u ] where τ i is the last weight read on the list L i . In other words, a threshold vector consists of the upper bounds on the weights of unseen instances in input lists. After reading an instance c r , C i,r in the list, L i , the possible worst score of the r-th position in the semantically reinterpreted document vector, {right arrow over (d)}′=[w′ 1 , w′ 2 , . . , w′ r , . . . , w′ m ], is computed as
[0000]
w
r
,
wst
′
=
∑
h
∈
KN
r
w
h
×
C
h
,
r
,
[0000] where K N r is a set of positions in the concept-vector, C−, r , whose corresponding weights have been read before by the algorithm. On the other hand, the possible best score of r-th position in {right arrow over (d)}′ is computed as follows:
[0000]
w
r
,
bst
′
=
∑
h
∈
KN
r
w
h
×
C
h
,
r
+
∑
j
∉
KN
r
w
j
×
μ
j
.
[0071] In summary, the possible worst score is computed based on the assumption that the unseen entries of the concept-vector will be 0, while the possible best score assumes that all unseen entries in the concept-vector will be encountered after the last scan position of each list. NRA maintains a cut off score, mink, equals to the lowest score in the current top-k candidates. NRA would stop the computation when a cut off score, mink, is greater than (or equal to) the highest best-score of concepts not belonging to the current top-k candidates. Although this stopping condition always guarantees to produce the correct top-k results (i.e., S k in our case), such stopping condition is overly pessimistic, assuming that all unknown values of each concept vector would be read after the current scan position of each list. This, however, is not the case especially for the sparse keyword-concept matrix where unknown values of each concept vector are expected to be 0 with a very high probability. Therefore, NRA may end up scanning the entire lists, which would be quite expensive.
[0072] Efficiently Interpreting a Document with Wikipedia Concepts
[0073] In this section, the algorithm is described for the efficient semantic interpreter using Wikipedia. The proposed algorithm consists of two phases: (1) computing the approximate top-k concepts, S A of a given document and (2) mapping an original document into the concept-space using S k,α .
Phase 1: Identifying the Approximate Top-k Concept, S k,α
[0074] As described above, the threshold-based algorithms are based on the assumption that given sorted-lists, each object has a single score in each list. The possible scores of unseen objects in NRA algorithm are computed based on this assumption. This assumption, however, does not hold for the sparse keyword-concept matrix where most of entries are 0. Thus, in this subsection, first a method is described to estimate the scores of unseen objects with the sparse keyword-concept matrix, and then present a method to obtain the approximate top-k concepts of a given document leveraging the expected scores.
Estimating the Bounds on the Number of Input Lists
[0075] Since the assumption that each object has a single score in each input list is not valid for a sparse keyword-concept matrix, in this subsection the aim is to correctly estimate a bound on the number of input lists where each object is expected to be found during the computation. A histogram is usually used to approximate data distributions (i.e., probability density function). Many existing approximate top-k processing algorithms maintain histograms for input lists and estimate the scores of unknown objects by convoluting histograms. Generally, approximate methods are more efficient than exact schemes. Nevertheless, considering that there are a huge number of lists for the keyword-concept matrix, maintaining such histograms and convoluting them in run-time for computing possible aggregated scores is not a viable solution. Thus, in order to achieve further efficiency, the data distribution of each inverted list is simplified by relying on the binomial distribution: i.e., the case in which an inverted list contains a given concept or the other one in which it does not. Such simplified data distribution does not cause a significant reduction in the quality of the top-k results, due to the extreme sparsity of the concept matrix.
[0076] Given a keyword l i and a keyword-concept matrix C, the length of the corresponding sorted list, L i , is defined as
[0000] | L i |=|{C i,r |C i,r >0 where 1 ≦r≦m}|.
[0000] Given a u×m keyword-concept matrix, C, we formulate the probability that an instance (c r , C i,r is in L i as
[0000]
L
i
m
.
[0077] Generally, the threshold-based algorithms sequentially scan the each sorted list. One can assume that the algorithm sequentially scans the first f i instances from the sorted list L i , and the instance c r , C i,r was not seen during the scans. Then, one can compute the probability, that an instance c r , C i,r will be found in the unscanned parts of the list L i (i.e., the remaining (|L i |−f i ) instances) as follows:
[0000]
P
〈
C
i
,
r
,
f
i
〉
=
L
i
-
f
i
m
-
f
i
.
[0078] Note that will be 1 under the assumption that each object has a single score in each input list (i.e., |L i ⊕=m). However, the keyword-concept matrix is extremely sparse, and thus, in most cases, is close to 0.
[0079] Given a document, d, and a corresponding u-dimensional vector, {right arrow over (d)}=[w 1 , w 2 , . . . , w u ]. Furthermore, given {right arrow over (d)}, let L be a set of sorted lists such that:
[0000] L−{L i |w i >0 where 1≦i≦u}.
[0080] In other words, L is a set of sorted lists whose corresponding words appear in a given document d. Other lists not in L do not contribute to the computation of the semantically reinterpreted vector, {right arrow over (d)}′, because their corresponding weights in the original vector {right arrow over (d)} equal to 0 ( FIG. 2 ).
[0081] Further, it can be assumed that the occurrences of words in a document are independent of each other. The word-independence assumption has long been used by many applications due to its simplicity. Let P found — exact(L, c r ,n) be the probability that the concept c r , which was not yet seen in any list so far, will be found in exactly n lists in L afterward. Then, the probability can be computed as follows:
[0000]
P
found
_
exact
(
ℒ
,
c
r
,
n
)
=
(
ℒ
n
)
P
〈
c
r
,
avg
〉
n
×
(
1
-
P
〈
c
r
,
avg
〉
)
ℒ
-
n
.
where
,
P
〈
c
r
,
avg
〉
=
1
ℒ
∑
L
i
∈
ℒ
P
〈
C
i
,
r
,
f
i
〉
.
[0000] Furthermore, one can compute the P found — upto(L,c r ,n ), the probability that a fully unseen concept c r will be found in up to n lists in L during the computation as follows:
[0000]
P
found
_
upto
(
ℒ
,
c
r
,
n
)
=
∑
0
≤
q
≤
n
P
found
_
exact
(
ℒ
,
c
r
,
q
)
.
[0000] Note that P found — upto(L,c r ,|L ) always equals to 1.
[0082] As described earlier, the objective is to find the approximate top-k concepts, S k,α , satisfying that at least ak answers in S k,α belong to the exact top-k results, S k . Given an application (or user) provided acceptable precision rate a, in order to compute the bound, b r , on the number of lists where a fully unavailable concept, c r , will be found, the value chosen is the smallest value br satisfying
[0000] P found — upto(L,C r ,b r ,)≧α.
[0083] In summary, b r is the smallest value satisfying the probability of an unseen concept c r being less than b r input lists is higher than an acceptable precision rate, α.
Computing Expected Score for Fully or Partially Unseen Object
[0084] Once one estimates the number of lists where any fully unseen object will be found, one can compute the expected scores of fully (or partially) unseen objects.
[0085] Given a current threshold vector t{right arrow over (h)}=[τ 1 , τ 2 , . . . , τ u ] and an original document vector {right arrow over (d)}=[w 1 , w 2 , . . . , w u ], we define W as follows:
[0000] W={w i ×τ i |1 ≦i≦u}.
[0000] Then, the expected score of the fully unseen concept c r is bounded by
[0000]
w
r
,
exp
′
≤
∑
1
≤
h
≤
b
r
W
h
,
[0000] where W h is the h-th largest value in W.
[0086] Each list in an inverted index is sorted on weights rather than concept IDs, which results in a partially available (seen) concept-vector of a given concept, c r , during the top-k computation. Thus, we also need to estimate the expected scores of partially seen objects. Let crbe a partially seen concept. Furthermore, let K N r be a set of positions in the concept-vector, C−. r , whose weights have been seen before by the algorithm. Then, the expected score of partially seen concept c r is defined as follows:
[0000]
If
KN
r
≥
b
r
,
then
w
r
,
exp
′
=
∑
h
∈
KN
r
w
h
×
C
h
,
r
.
Otherwise
,
w
r
,
exp
′
=
∑
h
∈
KN
r
w
h
×
C
h
,
r
+
∑
KN
r
+
1
≤
h
≤
b
r
W
h
.
[0087] Note that the expected score of any fully or partially seen concept, c r , will equal to the possible best score described above, when the bound, b r , on the number of input lists where c r will be found is same with L. However, the sparsity of the keyword-concept matrix guarantees that the expected scores are always less than the possible best scores.
The Algorithm
[0088] FIG.7 describes the pseudo-code for the proposed algorithm to efficiently compute the approximate top-k concepts, S k,α , of a given document. The algorithm first initializes the set of the approximate top-k, S k,α , the cut off score, min k , and the set of candidates, Cnd. The threshold vector, t{right arrow over (h)}, is initially set to [1, 1, . . . , 1. Initially, the expected score of any fully unseen concept is computed, as described in above (line 1-5).
[0089] Generally, the threshold algorithms visit or access input lists in a round-robin manner. In cases where the input lists have various lengths, however, this scheme can be inefficient, as resources are wasted for processing unpromising objects whose corresponding scores are relatively low, but are read early because they belong to short lists. To resolve this problem, the input lists are visited in a way to minimize the expected score of a fully unavailable concept. Intuitively, this enables the algorithm to stop the computation earlier by providing a higher cut off score, mink.
[0090] Given an original document vector, {right arrow over (d)}=[w 1 , w 2 , . . . , w u ], and a current threshold vector, t{right arrow over (h)}=τ 1 , τ 2 , . . , τ u ], to decide which input list will be read next time by the algorithm, a list L i (line 8) is desired such that:
[0000] ∀ L h ∈L−{L i } w h ×τ h <w i ×τ i .
[0091] The list satisfying the above condition guarantees to minimize the expected score of any unavailable concept, and thus provides the early stopping condition to the algorithm.
[0092] For a newly seen instance c r , C i,r in the list L i , we compute the corresponding worst score, w′ r,wst , is computed and the candidate list is updated with c r , w′ r,ust (line 9-11). The cut off score, min k , is selected such that min k equals to the k -th highest value of the worst scores in the current candidate set, Cnd (line 12). Then, the threshold vector is updated (line 13).
[0093] Between line 15 and 20, unpromising concepts are removed from the candidate set, which will not be in the top-k results with a high probability. For each concept, c p , in the current candidate set, the corresponding expected score, w′ p,exp is computed, as described in above. Note that each concept in the current candidate set corresponds to a partially seen concept. If the expected score, w′ p,exp , of the partially seen concept, c p , is less than the cut off score, the pair, c p , w′ p,uist is removed from the current candidate set, since this concept is not expected to be in the final top-k results with a high probability (line 18). In line 21, the expected score of any fully unseen concept is computed. The top-k computation stops only when the current candidate set contains k elements and the expected scores of fully unseen concepts are likely to be less than the cut off score (line 7).
[0000] Phase 2: Mapping a Document from the Keyword-Space into the Concept-Space
[0094] Once the approximate top-k concepts of a given document are identified, the next step is to map an original document from the keyword-space into the concept-space. FIG. 8 describes the pseudo-code for mapping an original document from the keyword-space into the concept-space using S k,α .
[0095] Initially, a semantically reinterpreted vector, {right arrow over (d)}′, is set to [0, 0, . . . , 0] (line 1). Since the algorithm in FIG. 4 stops before scanning full input lists, the concept-vectors of the concepts in S k,α are partially available. Therefore, for each concept in S k,α it is needed to estimate the expected scores with the partially seen concept-vectors, as explained above (line 3). Then, the corresponding entries in the semantically reinterpreted vector, {right arrow over (d)}′, are updated with the estimated scores (line 4). Finally, the algorithm returns a semantically re-interpreted document vector, {right arrow over (d)} (line 6). A novel semantic interpreter is described for efficiently enriching original documents based on concepts of the Wikipedia. The proposed approach enables to efficiently identify the most significant k -concepts in Wikipedia for a given document and leverage these concepts to semantically enrich an original document by mapping it from keyword-space to the concept-space. //Experimental results show that the proposed technique significantly improves efficiency of semantic reinterpretation without causing significant reduction in precision.
[0096] These and other features and advantages of the present principles may be readily ascertained by one of ordinary skill in the pertinent art based on the teachings herein. It is to be understood that the teachings of the present principles may be implemented in various forms of hardware, software, firmware, special purpose processors, or combinations thereof.
[0097] Most preferably, the teachings of the present principles are implemented as a combination of hardware and software. Moreover, the software may be implemented as an application program tangibly embodied on a program storage unit. The application program may be uploaded to, and executed by, a machine comprising any suitable architecture. Preferably, the machine is implemented on a computer platform having hardware such as one or more central processing units (“CPU”), a random access memory (“RAM”), and input/output (“I/O”) interfaces. The computer platform may also include an operating system and microinstruction code. The various processes and functions described herein may be either part of the microinstruction code or part of the application program, or any combination thereof, which may be executed by a CPU. In addition, various other peripheral units may be connected to the computer platform such as an additional data storage unit and a printing unit.
[0098] It is to be further understood that, because some of the constituent system components and methods depicted in the accompanying drawings are preferably implemented in software, the actual connections between the system components or the process function blocks may differ depending upon the manner in which the present principles are programmed. Given the teachings herein, one of ordinary skill in the pertinent art will be able to contemplate these and similar implementations or configurations of the present principles.
[0099] Although the illustrative embodiments have been described herein with reference to the accompanying drawings, it is to be understood that the present principles is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one of ordinary skill in the pertinent art without departing from the scope or spirit of the present principles. All such changes and modifications are intended to be included within the scope of the present principles as set forth in the appended claims.
|
Proper representation of the meaning of texts is crucial to enhancing many data mining and information retrieval tasks, including clustering, computing semantic relatedness between texts, and searching. Representing of texts in the concept-space derived from Wikipedia has received growing attention recently, due to its comprehensiveness and expertise. This concept-based representation is capable of extracting semantic relatedness between texts that cannot be deduced with the bag of words model. A key obstacle, however, for using Wikipedia as a semantic interpreter is that the sheer size of the concepts derived from Wikipedia makes it hard to efficiently map texts into concept-space. An efficient algorithm is proved which is able to represent the meaning of a text by using the concepts that best match it. In particular, this approach first computes the approximate top- concepts that are most relevant to the given text. These concepts are then leverage to represent the meaning of the given text.
| 6
|
RELATED APPLICATION
[0001] This application is a continuation-in-part application based upon prior filed utility application Ser. No. 11/671,757 filed Feb. 6, 2007, which is based upon provisional application Ser. No. 60/771,003 filed Feb. 7, 2006, the disclosures of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to dietary supplements, and, more particularly to the formulation of such supplements containing fatty alcohols.
BACKGROUND OF THE INVENTION
[0003] Cholesterol is an essential component in the body and used in cell membranes. Excessive levels, however, can lead to hypercholesterolemia and atherosclerosis, which can result in coronary heart disease. Cholesterol is transported via: high-, low-, intermediate-, and very low-density lipoproteins; chylomicron remants; and chylomicrons. High levels of high-density lipoproteins are desirable because they transport cholesterol from the peripheral tissues to the liver, thereby maintaining cholesterol homeostasis. The main transport mechanism, however, is low-density lipoprotein, which moves cholesterol in the blood plasma and incorporates it into cell membranes. Increased levels of low-density lipoprotein, however, can interfere with uptake binding mechanisms.
[0004] Statin drugs such as atorvastatin, fluvastatin, pravastatin and simvastatin are often administered to those suffering from cholesterol issues. These drugs inhibit competitively 3-hydroxy-3-methylglutaryl coenzyme A reductase, thereby reducing cholesterol synthesis. Side effects of statins can include myositis, headache, rash, angioedema, gastrointestinal effects and altered liver functions. In addition, these drugs should not be used in patients with renal failure or in people with compromised liver function (Taylor et al. 2003).
[0005] Dietary fatty acid intake can influence many health factors, but much interest has been placed on the n-3 (omega-3) fatty acids. These essential fatty acids include α-linolenic (ALA), eicosapentaenoic (EPA) and docosahexaenoic acid (DHA). Various studies have shown that n-3 fatty acids are essential for normal growth and development. They may also play a critical role in the prevention and treatment of coronary heart disease, hypertension, diabetes and other inflammatory and autoimmune disorders (Simopoulos 1999). ALA is present in certain vegetable oils (flaxseed, cranberry seed, canola and chia) whereas EPA and DHA are found in fish, fish oil and algae products.
[0006] Between ethnic dietary groups it has been shown that the higher ratio of n-6 to n-3 in thrombocyte phospholipids can be a cause for a higher death rate from cardiovascular disease. This increased ratio also results in increased rates of type 2 diabetes, of which atherosclerosis is a major complication (Weber, 1991). Achieving target levels of n-3 fatty acids can be difficult with modern western diets deficient in ALA, EPA and DHA, and excessive in the n-6 linoleic acid. Target tissue concentrations for ALA and EPA can be met with consumption of ALA (Mantzioris et al. 2000). A primary cardiovascular benefit from n-3 fatty acid ingestion can be reduced blood clotting in vessel walls and reduced ventricular arrhythmias, (Zhao et al. (2004)). Some studies have found a dose-response relation between n-3 intake and beneficial effects on cardiovascular disease risk factors. Some studies have shown an inverse relationship between ALA intake and risk of sudden cardiac death (Albert et al. (2005)).
[0007] Policosanols can be defined as a mixture of long chain (C24-C36) aliphatic primary alcohols, which are commonly derived from sugar cane, rice bran, beeswax, wheat or sorghum. Predominant alcohols in this group are tetracosanol, hexacosanol, octacosanol and triacontanol.
[0008] Policosanols can lower cholesterol levels by inhibiting cholesterol biosynthesis via downregulation of 3-hydroxy-3-methylglutaryl Coenzyme A enzyme expression (Menendez et al. 1994, McCarty 2002). A study by Hernandez et al. (1992) found a reduction in serum cholesterol levels of subjects taking 20 mg policosanol per day for 4 weeks. Significant decreases in LDL levels, with increased levels of HDL were also noticed. Another double-blind randomized study by Castano, et al. (1999) investigated the effects of policosanol and pravastatin on the lipid profile in older hypercholesterelemic patients. Policosanol was found to increase HDL levels, but was also more effective than pravastatin in lowering LDL levels and the LDL:HDL ratio.
[0009] Policosanols can also protect lipoproteins from peroxidation, in both lipid and protein moieties (Menendez et al. 1999). This can be an important effect, since LDL oxidation is thought to be a necessary step in the development of atherosclerosis.
[0010] Policocanols may provide fewer side effects than statins, increase HDL cholesterol levels and have a reduced cost (Taylor et al. 2003).
[0011] One issue with policosanols are poor solubility, and difficulty with absorbtion in the gut. Human studies with [ 3 H]-octacosanol showed the majority (81-91%) of total radioactivity was excredted in the feces, and only 1.2% of total radioactivity was found in urine (Mas, 2000).
[0012] Reducing parent the particle size of poorly solube compounds such as policosanol to a micron or sub-micron range, improved absorbtion and bioavailabilty is desirable.
[0013] Copending parent application Ser. No. 11/671,757 filed Feb. 7, 2006, discloses a human or animal dietary supplement composition that comprises a blood lipid health-effective amount of one or more long chain (C24-C36) primary alcohols (policosanols) dispersed in one or more food-grade fats or oils, wherein the particle sizes of the alcohols are substantially less than 10 microns.
SUMMARY OF THE INVENTION
[0014] During trials, it was found that positive and advantageous results further included reductions in base level for AST and ALT and an increase in the AST/ALT ratio. Also, there was a reduction in gastrointestinal esophageal reflux disease (GERD) symptoms and a reduction of irritable bowel syndrome symptoms.
[0015] In accordance with a non-limiting aspect, the method enhances gastrointestinal motility in humans and other mammals. The method comprises administering a therapeutically effective amount of a composition having one or more long chain (C24-C36) primary alcohols as policosanols dispersed in one or more food-grade fats or oils, wherein the particle sizes of the alcohols are substantially less than 10 microns.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Different embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments are shown. Many different forms can be set forth and described embodiments should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope to those skilled in the art.
[0017] The natural dietary supplement industry represents a $300 billion dollar marketplace worldwide. Many natural botanical materials and extracts have been used by mankind for health purposes for thousands of years. In some parts of the world, natural health products are preferred over chemical or pharmaceutical ones due to reasons of religion, culture, safety, cost and demonstrated efficacy.
[0018] Among the botanical products that have a history of use in support of human blood lipid health are certain fatty alcohols derived from botanical waxes, for example, sugar cane wax, rice bran and other cereal waxes and bees wax. The most important of these are the long chain (C24-C36) primary alcohols, octacosanol, triacontanol and hexacosanol.
[0019] Policosanols, as noted above, are known to have a number of beneficial effects on blood lipid health. These beneficial effects include lowering blood cholesterol levels, reducing Low Density Lipoproteins (LDL), increasing High Density Lipoproteins (HDL) and reducing blood triglycerides.
[0020] Some difficulties have been experienced in using policosanols to improve blood lipid health. For example, these fatty alcohols are poorly soluble in lipid carriers and completely insoluble in aqueous carriers. This greatly reduces their availability in the digestive tract. Normal digestion of fats and oils in the mammalian diet is achieved by emulsification with bile salts and phospholipids followed by direct adsorption of the resulting chylomicrons through the gut wall. Typical chylomicron sizes are 0.5 microns to 2 microns.
[0021] Modern emulsification technology (nanotechnology) now makes it possible to produce dispersed particle sizes in liquid carriers into the 1 micron size. As noted above, many different physical emulsification techniques are available.
[0022] In accordance with a non-limiting example of the present invention, one or more of these technologies is used to prepare a dietary supplement composition in which the policosanol particle sizes are substantially less than 10 micron range within an acceptable oil carrier (Nanocosanol™). The composition may include the use of food-grade emulsifiers, for example, polysorbates, lecithin, hydrolyzed lecithin, mono- and di-glycerides, and acylated mono- and di-glycerides. The presence of the emulsifiers inhibits the tendency of the particles to adhere under electrostatic attractive forces. Such a composition has the advantage of increased digestability and stability on storage.
[0023] In one aspect, the composition includes the selection of an oil carrier with beneficial blood lipid properties. Such fats and oils may include polyunsaturated fatty acids, omega-3 fatty acids, squalene, phytosterols, tocopherols and tocotrienols. Typical fats and oils include, for example, fish oils, shark liver oil, cranberry seed oil, amaranth seed oil, sunflower seed oil, linseed oil, chin oil and evening primrose seed oil.
[0024] In another aspect, the composition optimizes the balanced intake of both policosanols and the beneficial lipid carrier. By suitable selection of the ratio of the carrier oil to the policosanols, it is possible to produce the composition such that preferred intakes of both policosanols and the beneficial lipid can be conveniently administered in acceptable unit and daily doses.
[0025] Such a composition as (Nanocosanol™) can be used to promote and support blood lipid health. Daily intake of such composition, in the preferred dose range, will provide the subject with the desired daily intakes of policosanols and lipid carrier, resulting in improved blood lipid profiles. This can include, for example, lower cholesterol, lower triglycerides, lower Low Density Lipoprotein (LDL) and higher High Density Lipoprotein (HDL).
[0026] In accordance with one aspect of the present invention, a dietary supplement composition is disclosed (Nanocosanol™) in which poorly soluble policosanols are dispersed in food-grade oils or fats, in which the policosanol particle sizes in the composition are substantially less than 10 microns and preferably in the range of from about 0.2 microns to about 5.0 microns.
[0027] In accordance with another aspect of the present invention, the body's absorption and utilization of the policosanols from the composition is substantially enhanced as compared with the absorption and utilization of policosanols administered in solid or tablet form. The policosanol dispersion of the composition is stable on storage and does not separate from the lipid carrier.
[0028] The disclosed lipid carrier used in the composition may be selected from a group of oils and or fats that are known to have beneficial effects on blood lipid health. Such beneficial lipids, for example, may contain one or more of polyunsaturated fatty acids, phytosterols, omega-3 fatty acids, squalene, tocopherols and tocotrienols.
[0029] The concentration of policosanols of the composition optimizes the daily intake of both policosanols and the beneficial lipid carrier. The preferred daily intake of policosanols can be about 20-30 mg per day for an adult. The preferred daily intake for beneficial lipids, however, is often as high as from about 500 mg to 5,000 mg per day for an adult. The weight of policosanols in the disclosed composition is from about 0.3 percent by weight of beneficial lipid to about 5.0 percent by weight of beneficial lipid. Such a disclosed composition allows the ratio of beneficial lipid to policosanols to range from about 333:1 to about 20:1. This ratio ensures that a policosanol intake of about 25 mg per day is always in combination with from about 500 mg per day to about 5,000 mg per day of the beneficial lipid. The disclosed composition allows delivery of a preferred daily dose of both policosanols and beneficial lipid in a single formulation.
[0030] It will be understood by those in the art that liquid dietary supplement daily doses of from about 500 mg to about 5,000 mg can be conveniently delivered in capsules from about 500 mg to about 1,000 mg. For example, a three percent dispersion of policosanols in a beneficial lipid can conveniently supply 24 mg of policosanols per day together with 800 mg of beneficial lipid, when taken as two 400 mg capsules daily.
[0031] It will be understood by those in the art that such a composition, in capsule or liquid form, may be conveniently supplemented with other biologically active extracts and compounds, including, for example, vitamins, minerals, antioxidants, carotenoids, tocopherols, tocotrienols, phytosterols, fatty alcohols, polysaccharides and bioflavonoids.
[0032] The disclosed dietary supplement composition (Nanocosanol™) is a novel, improved, more efficient vehicle for the administration of policosanols in support of blood lipid health. It is effective in lowering the blood serum cholesterol level of both normal and hypercholesterolemic subjects.
[0033] The following examples are illustrative of the present invention, and are not to be construed as limiting thereof.
EXAMPLE 1
[0034] Supercritical CO 2 Extracts of Cranberry ( Vaccinium macrocarpon ) Seed, Amaranth ( Amaranthus hypochondriacus ) Seed and Rice ( Oryza sativa ) bran wax were individually manufactured in a commercial 150 liter extraction unit. Within a heated vessel, the policosanol containing rice bran wax extract was dissolved into a mixture of cranberry and amaranth seed oily extracts at 65° C. After cooling to ambient temperature, soybean lecithin was combined. This resultant formulation was processed in a high pressure homogenization unit to obtain a stable dispersion of rice bran wax. The homogenizer is designed to produce high rates of shear and cavitation. Using light microscopy, average particle size was determined. Composition of the dispersion was as follows:
Policosanols: 1.45%, average particle size 0.3-2.6 μm. alpha-Linolenic acid: 13.2% Squalene: 3% Tocopherols: 499 μg/g Tocotrienols: 709 μg/g Phytosterols: 4.4 mg/g
EXAMPLE 2
[0041] The Nanocosanol formulation from Example 1 was encapsulated in standard gelatin softgels by a third party manufacturer. Softgels were 690 mg nominal fill weight and each contained 10 mg policosanol, 21 mg squalene, 91 mg n-3 fatty acids (alpha-linolenic), 3.0 mg phytosterols, 489 μg tocotrienols and 344 μg tocopherols.
EXAMPLE 3
[0042] Nanocosanol™ softgels, manufactured according to Example 2 were administered to 11 subjects over an approximately 3-month period. The study was a non-placebo controlled open label trial and used volunteers with normal and modestly elevated levels of serum cholesterol. Starting point individual cholesterol levels ranged from about 140 to about 258. Dosage was 2×600 mg capsules per day providing 20 mg per day of policosanols together with 1200 mg per day of a 50:50 mixture of Cranberry and Amaranth Seed oils. In addition to the Policosonols, the Nanocosanol™ formulation provided tocopherols, tocotrienols, omega-6 and omega-3 fatty acids, polyunsaturated fatty acids and squalene.
[0043] Subject blood samples were taken by an independent clinic at 0 (Base), 30, 60 and 90 days. The blood samples were subjected to Blood Lipid by an authorized independent laboratory.
[0044] Variables measured were Triglycerides, Cholesterol, LDL Cholesterol and HDL Cholesterol.
[0045] All data were expressed as a difference (change) from the Base level for that subject and that variable. One subject did not complete a blood sample at 90 days so the total number of observations was 32 (11, 11, 10). Analyses were based the combined data over all three periods. The mean changes for the Blood Lipid variables were:
[0000]
Triglycerides
−4.72%
p = 0.175
LDL Chol.
−10.06%
p = 0.125
HDL Chol.
+1.85%
p = 0.175
OTHER Chol.
−5.23%
p = 0.125
Chol.
−5.96%
p = 0.050
LDL/HDL
−11.73%
p = 0.050
Chol/HDL
−7.43%
p = 0.050
[0046] The Cholesterol reduction of 5.96% was significant at the 5% level of probability using the One-Sided t-test with 31 DF, as were the LDL/HDL ratio and the Chol/HDL ratio. The other Blood Lipid decreases are not significant at the 5% Level but have only a 1 in 6 to about 1 in 8 chance of occurring by chance.
[0047] The mean changes for the blood liver variables were:
[0000]
AST
−7.06%
p = 0.050
ALT
−13.78%
p = 0.050
AST/ALT
+7.39%
p = 0.050
[0048] AST and ALT in the combined data were both significantly reduced at the 5% level of probability using the Two-Sided t-test with 31 DF. The AST/ALT ratio was significantly increased at the 5% level, as a result of ALT showing the greater reduction.
[0049] Analysis of Covariance was used to estimate the linear regression of variable change on variable Base level. The analyses tested the within-period regressions, differences between them, the pooled within period regression, the regression-adjusted means and the overall regression. Both the pooled within period regression coefficient and the overall regression coefficient for most variables were negative, highly significant at the 1% level (1 and 30 DF) and virtually identical.
[0050] Within period analyses for the Blood Lipid variables showed at least one period gave a significant regression of change on Base level at the 5% level with 1 and 9 DF. For all such variables except HDL the regression coefficients were negative in each period. For HDL the regression coefficients were positive in all three periods.
[0051] Within period analyses of the Blood Liver Variables showed consistent negative regression coefficients for AST and ALT although none were statistically significant.
[0052] All variables showed no evidence of within period differences between the regression coefficients or between the regression adjusted means. This would be expected given that the Base levels were identical for each period.
[0053] Both the pooled within period regression coefficient and the overall regression coefficient for most variables were negative, highly significant at the 1% level (1 and 30 DF) and virtually identical. The exceptions were HDL and AST/ALT.
[0054] Using the estimated regression equation, an estimate of the variable reduction resulting from a “typical high-quartile” Base level was calculated for each variable. These are shown as follows. No attempt was made to put Standard Errors on the estimates.
[0000]
Triglyceride
b = −0.2918
p < 0.010
Base = 200
Chng = −29.92
(−14.62%)
LDL
b = −0.8234
p < 0.010
Base = 150
Chng = −34.34
(−22.89%)
HDL
b = +0.0854
p = 0.175
OTHER Chol
b = −0.2870
p < 0.010
Base = 35
Chng = −4.43
(−12.66%)
Chol
b = −0.7704
p < 0.010
Base = 225
Chng = −24.27
(−10.78%)
LDL/HDL
b = −0.4534
p < 0.010
Base = 2.75
Chng = −0.52
(−18.89%)
Chol/HDL
b = −0.3577
p < 0.010
Base = 5.00
Chng = −0.78
(−15.52%)
AST
b = −0.5720
p < 0.010
Base = 25
Chng = −4.32
(−17.27%)
ALT
b = −0.3554
p < 0.010
Base = 25
Chng = −4.20
(−16.75%)
AST/ALT
b = −0.0661
N.S.
[0055] The treatment resulted in significant and near significant reductions over base level for all Blood Lipid variables except HDL which showed a small increase. This slight increase in HDL should be seen as being a positive result. Nanocosanol was clearly and demonstrably responsible for a significant improvement in blood lipid health. This is most clearly established for Total Cholesterol and the critical LDL/HDL and Chol/HDL ratios. It is also likely that in a larger sample size, the reductions in Triglycerides and LDL and the increase in HDL, both desirable treatment effects, could be confirmed as significant.
[0056] The treatment resulted in highly significant reductions over Base level for AST and ALT and an increase for the AST/ALT ratio. The reduction in blood aminotransferases is unexpected. These tests are designed to detect elevated values as an indicator of liver damage. However, it is not clear whether a reduction in these enzyme levels is an indicator of “improved” liver health. This aspect of the study requires further specific trial work.
[0057] The fact that significant results were obtained using all 32 data points but not with the 11 data points in each period, is possibly due to nothing other than sample size. However, it does point out that the reductions in Blood Lipid values occur fairly quickly following Nanocosanol treatment, with on-going reductions proceeding very slowly, if at all.
[0058] The most important result is the demonstration that decreases in both Blood Lipid and Blood Liver values are a function of the Base level. These results suggest that Nanocosanol will have very little effect on subjects with low to normal blood values. However for those subjects in the population with elevated values, Nanocosanol could have the potential to bring about 15-20% reductions in a very short time.
[0059] The positive side effects mentioned effects included a reduction in gastrointestinal esophageal reflux disease (GERD) symptoms (reported by 3 subjects) and reduction of irritable bowel syndrome symptoms was reported by one volunteer. Seven (64%) of the volunteers reported an increase in the number of bowl movements without a significant stool softening. In some cases the number of bowl movements increased twofold without any negative impacts. At each blood draw each volunteer was asked to fill out a report about any negative or positive side effects. Over half of the trial participants reported positive health impacts while zero negative side effects were reported.
[0060] Typically, the manifestation and improvements in irritable bowel syndrome could include not only a reduction in the number of bowel movements per day when those bowel movements are excessive, but also an increase in weekly bowel movements when the weekly bowel movements are minimal, such as only two or three bowel movements per week. Although the exact mechanism for the dietary or brain-gut response is not completely known, the results have been positive.
[0061] As to GERD, in some cases, it is typically caused by a failure of the cardia or minimal stomach acid. The method using the composition effectively counteracts such causes in some of the sampled subjects as noted above.
[0062] Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.
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A method for enhancing gastrointestinal motility in humans and other mammals comprises administering a therapeutically effective amount of a composition having one or more long chain (C24-C36) primary alcohols as policosanols dispersed in one or more food-grade fats or oils, wherein the particle sizes of the alcohols are substantially less than 10 microns.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to packages for merchandising items and, more particularly, to a convertible package for holding a wallet, bill-fold or the like on a rack or other support structure for display and merchandising, and which package can be converted to be used thereafter as a caddy or valet box for small personal items, e.g., jewelry.
[0003] 2. Description of Related Art
[0004] The merchandising of wallets, billfolds and the like is commonly effected by displaying those items on a display rack or suspended from horizontally projecting members, e.g., prongs or hooks.
[0005] In U.S. Letters Pat. No. 5,772,039 (Orr et al.) there is disclosed a packaging system for displaying an article, such as a wallet, in a manner such that the it is readily accessible to shoppers, but are relatively difficult to shoplift. The packaging system comprises three main elements: a box, a box insert, and an attachment mechanism which secures the wallet to the box insert. The box insert is then adhesively attached to the box.
[0006] In U.S. Letters Pat. No. 6,053,326 (Ford), which is assigned to the same assignee as the subject invention, there is disclosed another packaging system for a wallet or billfold to enable it to be opened and examined, while deterring its removal from the packaging system. The packaging system basically comprises a box and a band member formed of a tear resistant material, e.g., a flat strip of plastic, which extends through a portion of the wallet and is secured to the box. A lid is provided to cover the box. A flanged insert member may also be provided in the interior of the box to serve as a means for carrying visible indicia, e.g., the model designation of the wallet or billfold, a trademark, pricing information, etc.
[0007] Other patents disclose devices for merchandising wallets. For example, U.S. Letters Pat. No. 3,994,460 (Geiger) discloses a one-piece decorative display stand intended for use in displaying a variety of alternative types of merchandise items such as billfolds or the like in any number of generally vertically upstanding positions such that the item displayed is presented in an attractive manner to consumers. The display stand is generally comprised of a molded body which has a plurality of grooves for receiving billfolds, wallets or the like and for supporting them in a generally vertical position.
[0008] While the packages of the aforementioned prior patents appear generally suitable for their intended purposes, they still leave something to be desired from one or more of the standpoints of the utility of the packaging after the product has been purchased and the ability of the package to be suspended from a prong or other hanger of a conventional display rack or otherwise held vertically.
BRIEF SUMMARY OF THE INVENTION
[0009] A display package for an article, e.g., a wallet. The package is arranged to be hung from a support structure, e.g., a prong of a display rack, and comprises a tray and a housing. The tray is a box-like member having a base wall, a side wall extending about the periphery of the base wall, an open top and a hollow interior defined between the base wall and the side wall and in communication with the open top. The hollow interior of the tray is arranged for receipt of the article therein. The housing has a base wall, a side wall extending about a portion of the periphery of the base wall of the housing, an open top and a hollow interior defined between the base wall of the housing and the side wall of the housing and in communication with the open top of the housing. The side wall of the housing has a gap therein in communication with the hollow interior and the open top of the housing.
[0010] The tray is arranged to be located within the hollow interior of the housing, with the side wall of the tray being located adjacent the side wall of the housing and with the open top of the tray being located within the open top of the housing so that the article is visible therethrough.
[0011] The tray is also arranged to be slid out of the housing through the gap. A magnetic closure assembly is provided in the package for releasably holding the tray within the hollow interior of the housing.
[0012] The housing is adapted to be reversibly disposable with respect to the tray to form a lid for the tray, with the tray located within the hollow interior of the housing and with the base wall of the housing closing the open top of the tray, whereupon the hollow interior of the tray is totally enclosed.
[0013] In accordance with one preferred aspect of the invention the package includes a hanger releasably secured, e.g., adhesively releasably secured, to the housing to enable the package to be suspended or hung from a prong or other support member.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0014] The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:
[0015] FIG. 1 is an isometric view of one exemplary embodiment of convertible package of the subject invention shown holding a wallet therein and being suspended from a hook or prong of a conventional merchandising display rack or support;
[0016] FIG. 2 is an isometric view showing the package of FIG. 1 in the process of being opened;
[0017] FIG. 3 is an isometric view, similar to FIG. 2 , but showing the package after it has been converted into a personal item caddy or valet and shown in its closed or sealed configuration; and
[0018] FIG. 4 is a slightly enlarged sectional view taken along line 4 - 4 of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring now in greater detail to the various figures of the drawing, wherein like reference characters refer to like parts, one exemplary convertible package 20 constructed in accordance with this invention. The package 20 is initially configured as a display box to display a wallet 10 , bill fold or the like so that it can be seen and examined by potential purchasers, but is convertible thereafter to serve as a valet or caddy for small personal items.
[0020] The package basically comprises a tray 22 and a housing 24 . The housing is arranged so that when it is oriented in one manner it serves as receptacle for the tray and when reversed into another orientation, i.e., inverted, it serves as a cover or lid for the tray. To that end the tray is arranged to be initially nested or disposed within the housing 24 to form an open box-like assembly holding the wallet so that the wallet can be readily viewed and examined in a retail environment. After the package 20 with the wallet 10 therein has been purchased and brought home by the buyer, the wallet 10 can be readily removed for use. Unlike the wallet-holding boxes of the prior art as discussed above, which after the wallet has been removed are discarded, the package 20 of this invention is suitable for continued, albeit other, usage. In particular, after serving as the vending box for the wallet, the package 20 can be converted to be used as a valet, caddy or case for small personal items, e.g., jewelry, etc. In fact, if desired, it can still be used to hold the wallet when the wallet is not being used by the purchaser.
[0021] By virtue of its ability for dual usage, the convertible package of this invention can serve as a gift or premium to the purchaser of the wallet, by offering that purchaser additional value for his/her purchase of the wallet. Moreover, as will be appreciated from the discussion to follow the package 20 of this invention offers significant advantages to the manufacturer/retailer since it can be made for a small incremental cost over the cost of a disposable package, like the prior art, yet still provide an aesthetically pleasing and “rich-looking” appearance, thereby enhancing the prospect of selling the wallet.
[0022] The details of the tray will be described later. Suffice it for now to state that the tray 22 is of an open box-like configuration that includes a hollow interior which serves as the receptacle for initially holding the wallet 10 . The tray 22 is located within the housing 24 and is slidable with respect thereto. Thus, the tray 22 can be slid out of the housing 24 to enable the prospective purchaser to more closely examine the wallet 10 . The convertible package includes a magnetic assembly, to be described in detail later, to deter the accidental sliding of the tray out of the housing, particularly if the package 20 is oriented so that the force of gravity could cause the tray to drop out of the housing. This feature is of considerable importance when the package is in the retail environment to prevent the tray (with the wallet therein) from falling out of housing if the package is suspended from a hook or prong of a conventional display rack or if a potential buyer lifts the entire package off of its display rack or counter to examine it and holds it vertically.
[0023] When the package is no longer needed as a display box, e.g., after the package with the wallet has been purchased and brought home, the wallet can be removed and the package can be readily converted into a valet or caddy, wherein the hollow interior of the tray can be used for holding any other small item(s) to be stored. In particular, the housing can be inverted with respect to the tray from the orientation shown in FIGS. 1 and 2 to enable it to serve as a lid for the tray. To that end the inverted housing can be slid over to the tray to close off the interior of the tray as shown in FIG. 3 .
[0024] Referring now to FIGS. 1, 2 and 4 the details of the package will now be described. As can be seen the tray 22 basically comprises a box-like construction having a generally planar base wall 26 ( FIG. 4 ), a side wall 28 extending about the entire periphery of the base wall 26 and projecting perpendicularly thereto. The space between the inner surface of the base wall 26 and the inner surface of the side wall 28 defines a hollow interior cavity 30 . The top of the cavity 30 , i.e., the area bounded by the top surface of the side wall 28 , is open at 32 and in communication with the cavity 30 . The cavity 30 serves as the receptacle for the wallet 10 and any other items to be held within it after the wallet has been removed. In the exemplary embodiment shown the base wall 26 is of rectangular shape having four linear side edges 26 A, 26 B, 26 C and 26 D. The peripheral side wall 28 includes four generally planar sections 28 A, 28 B, 28 C and 28 D extending along the linear side edges, 26 A, 26 B, 26 C and 26 D, respectively, of the base wall 26 .
[0025] The housing 24 is somewhat similar in construction to the tray 22 and basically comprises a generally planar base wall 34 and a side wall 36 projecting perpendicularly thereto. The exemplary embodiment of the base wall 34 is of rectangular shape that is just slightly larger than the base wall 26 of the tray 22 and includes four linear side edges 34 A, 34 B, 34 C and 34 D. Unlike the tray 22 , the side wall 36 of the housing extends about only a portion of the periphery of its base wall 34 . Thus, the side wall 36 of the housing 24 includes only three sections 36 A, 36 B and 36 D, which extend along and project perpendicularly to the side edges 34 A, 34 B and 34 D, respectively, of the base wall 34 . The remaining side edge 34 D of the base wall 34 does not include any side wall section, i.e., there is a gap 38 in the side wall 36 along that edge. The volume bounded by the interior surfaces of the sections 36 A, 36 B and 36 C of the side wall 36 and the inner surface of the base wall 34 defines a hollow interior cavity 40 in communication with the gap 38 . This gap 38 serves as the entrance to slide the tray 22 into and out of the housing 24 . The top of the cavity 40 , i.e., the area bounded by the top surface of the side wall 36 , is open at 42 and is in communication with the cavity 40 .
[0026] The cavity 40 of the housing 24 serves as the receptacle for the tray 22 . To that end the tray is inserted into the cavity 40 of the housing by sliding it through the gap 38 in the side wall 36 like shown in FIG. 2 . When the tray is oriented so that its open top faces away from the base wall of the housing, such as shown in FIGS. 1 and 2 , the package 20 can serve as a display box for the wallet. If it is desired to dispose the package on a prong 12 or other horizontally projecting member of a conventional display rack (not shown), the package 20 may include a releasably securable hanger 44 . One exemplary hanger is the hang tag 44 shown in FIG. 1 . That tag basically comprises a flat strip or web of any suitable material, e.g., plastic. The strip includes a releasably securable adhesive, not shown, on one portion of its surface for releasable securement to the back surface of the base wall 34 of the housing 24 adjacent the peripheral wall section 36 A. The strip 44 also includes an opening 46 which is arranged to receive the prong or hanger 12 of the display rack (not shown) so that the package 20 can be suspended as shown in FIG. 1 .
[0027] As mentioned earlier the package 20 includes a magnetic assembly to prevent the tray from accidentally falling out of the housing, particularly, when the package is suspended from a prong as shown in FIG. 1 or when held in any similar orientation. The magnetic assembly 48 basically comprises a pair of magnets 50 and 52 . The magnet 50 is embedded centered within the section 36 A of the peripheral side wall 36 of the housing 24 , while a similar magnet 52 is embedded centered within the section 28 of the side wall 28 of the tray 22 . In the embodiment shown the two magnets are each shown as being disk-like members. That is merely exemplary of a myriad of shapes and sizes for the magnets 50 and 52 . In fact, both of those components need not be magnets. Thus, for example, one of the components 50 or 52 can be a magnet, while the other is merely a ferromagnetic material. The components 50 and 52 are preferably embedded in their respective side wall sections to render them invisible in the interest of aesthetics.
[0028] The tray and housing are preferably formed of any relatively inexpensive, rigid material, e.g., paperboard, plastic, wood, metal or combinations thereof, with the type of material used being a function of the desired cost for producing the package. For low cost applications the tray and housing may be formed of paperboard or similar low cost materials and having a film or other covering thereon which bears graphics and/or textures to simulate higher cost materials, e.g., a fine wood or metal.
[0029] It should be pointed out at this juncture that the shape, size and construction of the housing and tray as shown and described above is merely exemplary of numerous shapes and sizes of packages that can be made in accordance with this invention. Moreover, while the package has been shown and described for merchandising a wallet or billfold, that is merely one example of various products that can be merchandised using such packages. Further still, the packages of this invention may be used with other types of hangers than the hang tag described above. In fact, the package need not be used with any device for hanging it. Thus, it can be used by merely disposing it on some support surface, e.g., on a shelf of a rack or counter, etc.
[0030] While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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A convertible display package and a wallet arranged to be hung from a support. The package includes a tray and a housing. The tray has a base wall, a peripheral side wall, an open top and a hollow interior. The wallet is located within the tray's interior. The housing is similarly constructed, except that its side wall includes a gap. The tray is arranged to be located within the housing, with its sidewall adjacent the housing's sidewall and with its open top within the housing's open top so that the wallet is visible. The tray is arranged to be slid out of the housing through the gap. A pair of magnets are provided for releasably holding the tray within the housing. The housing can be reversibly disposed with respect to the tray to form a lid with the base wall of the housing closing the open top of the tray.
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DESCRIPTION
[0001] The present invention relates to a process for distillative removal of part or all of an azepine derivative (III) selected from the group consisting of tetrahydroazepine, 2-aminoazepan, N-(2-azepano)-1,6-diaminohexane and N-(2-azepano)-6-aminocapronitrile from a mixture (II) comprising an azepine derivative (III) and an amine (I) selected from the group consisting of 6-aminocapronitrile and hexamethylenediamine, which comprises conducting the distillation at a pot temperature of not more than 120° C.
[0002] Mixtures comprising an amine and an azepine derivative are customarily obtained in the hydrogenation of nitriles to amines.
[0003] The complete hydrogenation of adiponitrile (ADN) to hexamethylenediamine (HMD), and also the partial hydrogenation with coproduction of HMD and 6-aminocapronitrile (ACN), in the presence of a catalyst based on a metal such as nickel, cobalt, iron, rhodium or ruthenium is commonly known, for example from: K. Weissermel, H. -J. Arpe, Industrielle Organische Chemie, 3rd edition, VCH Verlagsgesellschaft mbH, Weinheim, 1988, page 266, U.S. Pat. Nos. 4,601,859, 2,762,835, 2,208,598, DE-A 848 654, DE-A 954 416, DE-A 42 35 466, U.S. Pat. No. 3,696,153, DE-A 19500222, WO-A-92/21650 and DE-A-19548289.
[0004] By-products formed include azepine derivatives such as N-(2-azepano)-1,6-diaminohexane and N-(2-azepano)-6-amino-capronitrile, especially 2-aminoazepan and tetrahydroazepine.
[0005] These azepine derivatives, which, because of their color and deleterious effect on product properties, constitute undesirable impurities in the amines, which are customarily used for manufacturing fibers, are difficult to separate from the amines.
[0006] For instance, GB-A-893 709 discloses installing a delay time vessel in the reflux line of a distillation column used for purifying HMD.
[0007] GB-A-1 238 351 describes the removal of HMD from mixtures comprising HMD and azepine derivatives, by addition of alkali metal hydroxide mixtures.
[0008] WO-A-99/48872 discloses distillatively removing azepine derivatives from amines at overhead temperatures of from 160 to 250° C. The disadvantage with this process is unsatisfactory separation.
[0009] Disadvantages with the processes mentioned are the use of large vessels, which makes for reduced control of the distillation columns, and the formation of solids, which can lead to blockages, and unsatisfactory removal of the azepine derivatives.
[0010] It is an object of the present invention to provide a process for removing an azepine derivative from mixtures comprising an amine and an azepine derivative in a technically simple and economical manner.
[0011] We have found that this object is achieved by the process defined at the beginning.
[0012] Suitable amines I include aromatic amines such as benzylamine, aliphatic amines such as cyclic amines, for example isophorone-diamine, or preferably acyclic amines, for example 1,4-diamino-butane, especially HMD or ACN, and also mixtures thereof.
[0013] Such amines can be prepared in a conventional manner.
[0014] For instance, HMD can be obtained by partial or complete catalytic hydrogenation with a gas comprising molecular hydrogen, of ADN to HMD or mixtures comprising HMD and ACN.
[0015] Catalysts used for this hydrogenation can advantageously be those based on a metal selected from the group consisting of ruthenium, rhodium, nickel, cobalt, preferably iron, in which case the catalysts may include further elements as promoters. In the case of iron-based catalysts, suitable promoters include especially one or more, such as two, three, four or five, elements selected from the group consisting of aluminum, silicon, zirconium, titanium and vanadium.
[0016] Such catalysts and the process conditions for the reaction mentioned are described for example in WO-A-96/20166, DE-A-19636768 and DE-A-19646436.
[0017] Contemplated azepine derivatives III include especially 2-aminoazepan of the formula
[0018] N-(2-azepano)-1,6-diaminohexane of the formula
[0019] N-(2-azepano)-6-aminocapronitrile
[0020] and THA of the formula
[0021] and mixtures thereof.
[0022] The azepine derivatives (III) can be present in the mixture (II) as individual compounds or as adducts, for example with an amine (I), in which case these adducts shall for the purposes of the present invention likewise be termed azepine derivatives (III).
[0023] Such azepine derivatives and processes for their preparation are commonly known.
[0024] For instance, 2-aminoazepan, N-(2-azepano)-1,6-diaminohexane and N-(2-azepano)-6-aminocapronitrile and tetrahydroazepine can generally be obtained in mixtures (II) in amounts from 1 to 10,000 ppm, based on the mixture, in the partial catalytic hydrogenation of ADN with a gas comprising molecular hydrogen to form HMD or mixtures comprising HMD and ACN according to the process described for preparing the amines (I). Similarly, the azepine derivatives mentioned can be formed by oxidation of amines, such as HMD and ACN, for example with gases containing molecular oxygen.
[0025] According to the present invention, the distillation is conducted with pot temperatures of not more than 120° C., preferably not more than 110° C. The distillation is advantageously carried out at pot temperatures of not less than 50° C., preferably not less than 80° C.
[0026] The distillation can be carried out continuously.
[0027] The distillation can be carried out batchwise.
[0028] When HMD is used as amine (I) and one or more compounds selected from the group consisting of AHI, HHA, AHHA and THA as azepine derivative (III), then the distillation pressure, as measured at the bottom of the distillation apparatus, should be within the range from 1 to 300 mbar, preferably within the range from 5 to 100 mbar, especially within the range from 10 to 60 mbar.
[0029] When ACN is used as amine (I) and one or more compounds selected from the group consisting of 2-aminoazepan, N-(2-azepano)-1,6-diaminohexane and N-(2-azepano)-6-aminocapronitrile and tetrahydroazepine as azepine derivative (III), then the distillation pressure, as measured at the bottom of the distillation apparatus, should be within the range from 1 to 200 mbar, preferably within the range from 5 to 100 mbar, especially within the range from 10 to 40 mbar.
[0030] Advantageously, amine (I) is obtained above the feed of mixture (II) to the distillation apparatus, especially at the top of the distillation apparatus.
[0031] Advantageously the distillation provides a bottom product (VI) having a higher weight fraction of azepine derivative (III) than mixture (II).
[0032] Suitable apparatus for the distillation is any customary distillation apparatus as described for example in Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd Ed., Vol. 7, John Wiley & Sons, New York, 1979, pages 870-881, such as sieve plate columns, bubble cap columns or columns packed with arranged or dumped packing.
[0033] The distillation can be carried out in a plurality of columns, such as 2 or 3, but is advantageously carried out in a single column.
[0034] In a preferred embodiment, the distillation can be carried out in two stages.
[0035] The first stage can consist of a plurality of columns, such as 2 or 3, advantageously a single column. The second stage can consist of a plurality of columns, such as 2 or 3, advantageously a single column.
[0036] Advantageously the pressure in the first stage, measured in the pot, is at least 1.5 times, especially at least double, the pressure in the second stage, measured in the pot.
[0037] Advantageously not less than 20% by weight of the amount fed into the first stage per unit time is removed from the pot of the first stage and fed to the second stage.
[0038] Advantageously the overhead product of the second stage can be recycled into the first stage.
[0039] Advantageously the distillation mixture has added to it a compound (IV) whose boiling point is above that of said amine (I) under the distillation conditions. Compounds (V) useful for this purpose are in particular compounds (V) that are inert to the amine (I) under the distillation conditions.
[0040] Useful compounds (IV) include compounds from the group consisting of aromatics, aliphatics, such as cyclic and acyclic aliphatics, and aliphatic-aromatic compounds. These compounds may bear substituents, such as a hydroxyl, keto, ester, alkyl, aryl, cycloalkyl, arylalkyl group, preferably a nitrile or amino group, or a plurality of identical or different such groups.
[0041] Said compound (IV) can be a single compound or a mixture of such compounds.
[0042] Advantageous compounds (IV) are convertible in a simple manner, as by catalytic hydrogenation with a gas containing molecular hydrogen, for example, into a mixture (V) comprising an amine (I) and an amine (III) or in particular a mixture (II).
[0043] The products obtained in this conversion can be advantageously reused in the process of the invention.
[0044] The difference in the boiling points between the amine (I) and the compound (IV) should be from 1 to 200° C., preferably from 5 to 100° C., under the distillation conditions.
[0045] The compound (IV) can be added to the mixture (II) before or during the distillation.
[0046] The addition of the compound (IV) to the mixture (II) before the distillation can be carried out in the conventional manner in customary mixing apparatuses. With this procedure, the addition of a mixture of mixture (II) and compound (IV) into the distillation apparatus is contemplated.
[0047] The addition of the compound (IV) to the mixture (II) during the distillation can be effected by feeding the compound (IV) into the distillation apparatus preferably in the bottom region.
[0048] The distillation can advantageously be carried out in the presence of assistants which support the distillative separation of the invention, especially in the presence of carbon dioxide.
[0049] The concentration of azepine derivative (III) in the pot, based on the mixture present in the pot, is not more than 0.5% by weight, preferably not more than 0.2% by weight, especially not more than 0.15% by weight, during the distillation.
[0050] The process of the invention customarily affords the predominant proportion of azepine derivative (III) as bottom product (VI). This bottom product (VI) customarily includes azepine (III) in a higher weight concentration than the mixture (II) used for distillation according to the process of the invention (II).
[0051] Bottom product (VI) can advantageously be subjected in a conventional manner, for example according to the processes already mentioned for preparing HMD or mixtures comprising HMD and ACN, to a catalytic hydrogenation to obtain an amine (I), such as HMD or mixtures comprising HMD and ACN. In the hydrogenation, azepine derivative (III) can be converted into organic compounds, such as hexamethylimine, which mixed with amine (I) permit removal of amine (I) in a technically simple and economical manner.
[0052] HMD and ACN are intermediates for industrially important polyamides, such as nylon-6 or nylon-6,6.
EXAMPLES
[0053] Percentages are by weight, unless otherwise stated.
[0054] THA is tetrahydroazepine.
[0055] The product mixtures were analyzed by gas chromatography. THA concentrations below 20 ppm were determined by polarography.
Inventive Example
[0056] 50 kg/h of HMD having a THA content of 71 ppm were fed at a uniform rate to a distillation column having 50 theoretical plates and 41 kg/h of overhead product and 9 kg/h of bottom product were removed from the distillation apparatus at a reflux ratio of 1, a base-of-column pressure of 73 mbar and a pot temperature of 119.9° C.
[0057] The overhead product as well as HMD included 12 ppm of THA, the bottom product 334 ppm of THA.
Comparative Example
[0058] The inventive example was repeated except that the base-of-column pressure was 255 mbar and the pot temperature 153.5° C. The overhead product as well as HMD included 44 ppm of THA, the bottom product 172 ppm of THA.
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The invention relates to a method for separating by distillation a portion or the entirety of an azeptine derivative (III), which is selected from the group consisting of aminohexylidene imine, tetrahydroazepine, hexylhexahydroazepine and of aminohexylhexahydroazepine, out of a mixture (II) containing an azepine derivative (III) and an amine (I). The inventive method is characterized in that the distillation is carried out with a maximum bottom temperature of 150° C.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for linking data between a computer and a portable remote terminal and a data linking method therefor and, more particularly, to a system for linking data between a computer and a portable remote terminal enabling data extracted from a personal computer into a portable remote terminal to be edited and applied freely and a data linking method therefor.
2. Description of the Related Art
In recent years, more and more cases occur in business etc. where various information in a data base on a computer at an office is brought out by a portable remote terminal to user's destination and is made the most of. Conducted, for example, are bringing out customer's information into a portable remote terminal and referring to/editing the information, or bringing information of a product of outside trade into a portable remote terminal and referring to the information, or bringing out information about business negotiations that a user currently has into a portable remote terminal and making the most of the information.
In a case where data on a data base of a personal computer is read into a portable remote terminal and the portable remote terminal is brought to a user' destination to use the data, when a volume of data is large, much time is conventionally cost for the processing of extracting data from the personal computer into the portable remote terminal and the processing of synchronizing the terminal with the personal computer which is conducted when data editing is executed on the portable remote terminal because the data in the personal computer is taken in as it is into the portable remote terminal.
Also in conventional systems, data in a data base is taken in as it is into a portable remote terminal to result in bringing out data that needs not to be brought out by the portable remote terminal as well, which hinders operation and application when necessary data is actually referred to by the portable remote terminal.
Among conventional art related to data link between computers are, for example, distributed data base management systems disclosed in Japanese Patent Laying-Open (Kokai) No. Heisei 8-305714 and Japanese Patent Laying-Open (Kokai) No. Heisei 2-58165.
Disclosed in Japanese Patent Laying-Open (Kokai) No. Heisei 5-89004 is a technique of downloading a data base of a host computer into a portable remote terminal and uploading data updated offline by the portable remote terminal into the host computer in synchronization with the host computer.
The above-described conventional data link between a personal computer and a portable remote terminal has such problems as set forth below.
First, since data on the personal computer is taken in into the portable remote terminal as it is, when a volume of data is large, much time is cost for the processing of extracting data from the personal computer into the portable remote terminal and the processing of synchronizing the terminal with the personal computer which is conducted when data edging is executed on the portable remote terminal.
Secondly, in a conventional system, data in a data base is taken in into a portable remote terminal as it is to result in bringing out data that needs not to be brought out by the portable remote terminal as well, which hinders quick application of data when necessary data is actually referred to by the portable remote terminal.
Thirdly, since data taken in into a portable remote terminal should be synchronized with a host data base on a computer, the order of items of data on the portable remote terminal can not be changed by a user as required. This prevents efficient use of data.
Although Japanese Patent Laying-Open (Kokai) No. Heisei 5-89004 discloses a system of downloading a data base of a host computer into a portable remote terminal and uploading data updated offline by the portable remote terminal into the host computer in synchronization with the host computer, the system only provides synchronization of the data updated on the portable remote terminal based on user ID and fails to solve none of the above-described problems.
Also, the distributed data base management systems disclosed in the above-described Japanese Patent Laying-Open (Kokai) No. Heisei 8-305714 and Japanese Patent Laying-Open No. 2-58165 relate to a technique of providing synchronization of data bases dispersedly arranged at a plurality of sites connected through LAN, they recite none of a technique of bringing out a data base on a computer into a portable remote terminal to conduct reference/editing and synchronous processing as well.
SUMMARY OF THE INVENTION
A first object of the present invention is to provide a system for linking data between a personal computer and a portable remote terminal which enables execution of the processing of extracting data from the personal computer into the portable remote terminal and the processing of synchronizing the portable remote terminal with the personal computer in a short time period, and a data linking method therefor.
A second object of the present invention is to provide a system for linking data between a personal computer and a portable remote terminal which realizes quick application of data by selectively taking in data that needs to be brought out from a data base of the computer by the portable remote terminal, and a data linking method therefor.
A third object of the present invention is to provide a system for linking data between a personal computer and a portable remote terminal which enables the order of items of data taken in into the portable remote terminal to be changed by a user as required, thereby realizing efficient use of data, and a data linking method therefor.
According to the first aspect of the invention, a system for linking data between a computer and a portable remote terminal which extracts data of a host data base on the computer into the portable remote terminal, displays and edits the extracted data on the portable remote terminal and conducts synchronous processing of updated data in the portable remote terminal and a data base in the computer, wherein
the computer comprissing
means for selecting object data to be brought out from the host data base into the portable remote terminal and a record item of the object data,
means for creating on the portable remote terminal, with respect to selected object data, an item definition data base which defines a record attribute, an object storage data base which stores object data on a record basis correspondingly to the item definition data base, a relation definition data base which defines relations among object data stored in the object storage data base and a definition data base which defines relations among the respective data bases created,
means for writing, on the basis of a record taken out from the host data base, data into the corresponding one of the object storage data bases according to the item definition data base, and
synchronization means for conducting synchronous processing of reading updated data from the object storage data base of the portable remote terminal and writing the data into the host data base of the computer, and
the portable remote terminal comprising
means for conducting, when a record item of the object storage data base refers to other the object storage data base, link data solution processing based on a record attribute of the item definition data base, and
means for changing, when the display order of object data of the object storage data base is changed or when existence/non-existence of display is selected, the display order of object data of the item definition data base or an attribute indicative of existence/non-existence of display according to the contents of the change or the selection, and wherein
the synchronization means of the computer reads an updated record from the object storage data base of the portable remote terminal to update the host data base of the computer.
In the preferred construction, the portable remote terminal further comprises updating flag setting means for setting, when updating or addition of a record is made of the object storage data base, an updating flag at the corresponding record of the object storage data base.
In another preferred construction, the portable remote terminal further comprises editing means for editing object data stored in the object storage data base and conducting change of the display order of data items or selection of existence/non-existence of display.
In another preferred construction, the portable remote terminal further comprises updating flag setting means for setting, when updating or addition of a record is made of the object storage data base, an updating flag at the corresponding record of the object storage data base, and wherein the updating flag setting means, when updating or addition of a record is made of the object storage data base, sets a flag indicating that the object storage data base in question is updated at the definition data base, and the synchronization means searches the object storage data base updated by a flag of the definition data base and reads a record at which the object storage data base updating flag searched is set to update the host data base of the computer.
In another preferred construction, for each record item, the item definition data base has, as attributes, other object storage data base to be referred to by the record item in question and a record item, a record item with which the record item in question links, and a record item of an object storage data base to be referred to by the linked record item.
According to the second aspect of the invention, a method of linking data between a computer and a portable remote terminal which extracts data of a host data base on the computer into the portable remote terminal, displays and edits the extracted data on the portable remote terminal and conducts synchronous processing of updated data in the portable remote terminal and a data base in the computer, comprising
the steps of the computer of:
with respect to object data to be brought out into the portable remote terminal which is selected from the host data base and a record item of the object data, creating, on the portable remote terminal, an item definition data base which defines a record attribute, an object storage data base which stores object data on a record basis correspondingly to the item definition data base, a relation definition data base which defines relations among object data stored in the object storage data base and a definition data base which defines relations among the respective data bases created,
on the basis of a record taken out from the host data base, writing data into the corresponding one of the object storage data bases according to the item definition data base, and
conducting synchronous processing of reading updated data from the object storage data base of the portable remote terminal and writing the data into the host data base of the computer,
the steps of the portable remote terminal of:
when a record item of the object storage data base refers to other the object storage data base, conducting link data solution processing based on a record attribute of the item definition data base, and
when the display order of object data of the object storage data base is changed or when existence/non-existence of display is selected, changing the display order of object data of the item definition data base or an attribute indicative of existence/non-existence of display according to the contents of the change or the selection, and
the step of the computer of reading an updated record from the object storage data base of the portable remote terminal to update the host data base of the computer.
In the preferred construction, the method of linking data between a computer and a portable remote terminal further comprising
the step of the portable remote terminal of,
when updating or addition of a record is made of the object storage data base, setting an updating flag at the corresponding record of the object storage data base.
In another preferred construction, the method of linking data between a computer and a portable remote terminal further comprising
the steps of the portable remote terminal of:
when updating or addition of a record is made of the object storage data base, setting an updating flag at the corresponding record of the object storage data base and further setting a flag indicating that the object storage data base in question is updated at the definition data base, wherein
in synchronous processing of the computer, the object storage data base updated by a flag of the definition data base is searched and a record at which the object storage data base updating flag searched is set is read to update the host data base of the computer.
According to another aspect of the invention, a computer readable memory which stores a program for linking data between a computer and a portable remote terminal which extracts data of a host data base on the computer into the portable remote terminal, displays and edits the extracted data on the portable remote terminal and conducts synchronous processing of updated data in the portable remote terminal and a data base in the computer, wherein
the data link program comprises the steps of:
on the side of the computer
with respect to object data to be brought out into the portable remote terminal which is selected from the host data base and a record item of the object data, creating, on the portable remote terminal, an item definition data base which defines a record attribute, an object storage data base which stores object data on a record basis correspondingly to the item definition data base, a relation definition data base which defines relations among object data stored in the object storage data base and a definition data base which defines relations among the respective data bases created,
on the basis of a record taken out from the host data base, writing data into the corresponding one of the object storage data bases according to the item definition data base, and
conducting synchronous processing of reading updated data from the object storage data base of the portable remote terminal and writing the data into the host data base of the computer,
on the side of the portable remote terminal
when a record item of the object storage data base refers to other the object storage data base, conducting link data solution processing based on a record attribute of the item definition data base, and
when the display order of object data of the object storage data base is changed or when existence/non-existence of display is selected, changing the display order of object data of the item definition data base or an attribute indicative of existence/non-existence of display according to the contents of the change or the selection, and
on the computer, reading an updated record from the object storage data base of the portable remote terminal to update the host data base of the computer.
Other objects, features and advantages of the present invention will become clear from the detailed description given herebelow.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the invention, which, however, should not be taken to be limitative to the invention, but are for explanation and understanding only.
In the drawings:
FIG. 1 is a diagram showing system structure of a data link system for linking data between a personal computer and a portable remote terminal according to an embodiment of the present invention;
FIG. 2 is a diagram showing program module structure of the personal computer and the portable remote terminal realizing the data link system of the present invention;
FIG. 3 is a diagram showing each program of the personal computer and the portable remote terminal of the present invention and arrangement of a generated DB in the portable remote terminal;
FIG. 4 is a diagram showing table arrangement of a data base definition DB in the DB on the portable remote terminal of the present invention;
FIG. 5 is a diagram showing table arrangement of an item definition DB in the DB on the portable remote terminal of the present invention;
FIG. 6 is a diagram showing table arrangement of a relation definition DB in the DB on the portable remote terminal of the present invention;
FIG. 7 is a diagram showing table arrangement of a user's selection item DB in the DB on the portable remote terminal of the present invention;
FIG. 8 is a diagram showing table arrangement of an object storage DB in the DB on the portable remote terminal of the present invention;
FIG. 9 is a flow chart for use in explaining the contents of initialization processing by an application program of the personal computer of the present invention;
FIG. 10 is a flow chart for use in explaining the contents of the processing of synchronizing the personal computer and the portable remote terminal of the present invention;
FIG. 11 is a diagram showing an example of display screen on which a user selects the order of data items to be displayed in data editing on the portable remote terminal of the present invention;
FIG. 12 is a diagram showing an example of data editing screen on the portable remote terminal of the present invention;
FIG. 13 is a diagram showing an example of data editing screen on the portable remote terminal of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention will be discussed hereinafter in detail with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without these specific details. In other instance, well-known structures are not shown in detail in order to unnecessary obscure the present invention.
FIG. 1 is a diagram showing system structure of a data link system for linking data between a personal computer and a portable remote terminal according to the embodiment of the present invention.
The data link system is structured to have a personal computer 10 and a portable remote terminal 11 connected through a connection cable 12 , thereby enabling data transmission and reception between the computer and the terminal. 13 denotes an input means (pen) for performing data editing (display and input) on the portable remote terminal 11 . The portable remote terminal 11 arbitrarily extracts part of data of a data base (DB) in the personal computer 10 to edit data (display/modification/input).
FIG. 2 is a diagram showing program module structure of the personal computer 10 and the portable remote terminal 11 realizing the data link system of the present invention. The program module of the personal computer 10 is composed of an operating system A 20 and an application program A 21 and has a host DB 22 . The program module of the portable remote terminal 11 is composed of an operating system B 30 and an application program B 31 and has a DB 40 .
Control for sending and receiving DB data is given by the operating system A 20 and the operating system B 30 . An arrow PO indicates a direction of program control made when the DB 40 is accessed by the application program A 21 of the personal computer 10 .
FIG. 3 shows each program of the personal computer 10 and the portable remote terminal 11 and DB arrangement of the generated DB 40 in the portable remote terminal 11 .
As illustrated in the figure, the DB 40 of the portable remote terminal 11 is composed of a data base definition DB 41 , an item definition DB 42 , a relation definition DB 43 , a user's selection item DB 44 and an object storage DB ( 45 a , 45 b , 45 c , . . . 45 n ).
Display and editing on the portable remote terminal 11 are executed with respect to data within the DB 40 by the application program B 31 . FIG. 11 shows an example of a display screen 210 on which a user selects the order of data items to be displayed in data editing (display/input) conducted by the application program B 31 on the portable remote terminal 11 . FIGS. 12 and 13 each show an example of a screen for data editing conducted on the portable remote terminal 11 by the application program B 31 of the portable remote terminal 11 .
FIGS. 4 to 8 show structure of the DB 40 on the portable remote terminal 11 .
FIG. 4 is a diagram showing table arrangement of the data base definition DB 41 of FIG. 3 . 41 - 1 ˜ 41 - 4 each show a column of the data base definition DB 41 . 411 ˜ 416 denote records where data is stored.
FIG. 5 is a diagram showing table arrangement of the item definition DB 42 of FIG. 3 . 42 - 1 ˜ 42 - 13 each show a column of the item definition DB 42 . 421 ˜ 425 denote records where data is stored.
FIG. 6 is a diagram showing table arrangement of the relation definition DB 43 of FIG. 3 . 43 - 1 ˜ 43 - 3 each denote a column of the relation definition DB 43 .
FIG. 7 is a diagram showing table arrangement of the user's selection item DB 44 of FIG. 3 . 44 - 1 ˜ 44 - 3 each denote a column of the user's selection item DB 44 .
FIG. 8 is a diagram showing table arrangement of the object storage DBs 45 a , 45 b , 45 c , . . . , 45 n . 45 - 1 ˜ 45 - 10 each denote a column of the object storage DB 45 . The object storage DB 45 a represents an object storage DB of a company indicated by the record 415 of the data base definition DB 41 , while the object storage DB 45 b represents an object storage DB of a product indicated by the record 416 of the data base definition DB 41 .
Detailed description will be here made of functions and table arrangement of the above-described DB 40 on the portable remote terminal 11 .
(a) Data Base Definition DB 41
The record 411 represents information of user ID (description of “ 123 ” here denotes the number of user ID), the record 412 represents the item definition DB 42 , the record 413 represents the relation definition DB 43 , the record 414 represents the user's selection item DB 44 , and the records 415 and 416 define relations of various data bases of the object storage DBs 45 a and 45 b . The data base definition DB 41 exists only one within the portable remote terminal 11 .
In the data base definition DB 41 of FIG. 4, a DB name 41 - 1 represents a name or a user ID which unitarily identifies a data base. A DB attribute 41 - 2 represents a data base attribute. Here, DB_USERID is an attribute indicative of a user ID, DB_DEFINE is an attribute indicative of the item definition DB, DB_RELATE is an attribute indicative of the relation definition DB, DB_CHOICE is an attribute indicative of the user's selection item DB and DB_RECORD is an attribute indicative of the object storage DB.
A synchronization time and date 41 - 3 represents a time stamp when synchronous processing of a data base is conducted. A DB updating flag 41 - 4 is a flag of a data base to be updated which represents an object not to be synchronized as “0” and an object to be synchronized as “1”.
(b) Item Definition DB 42
The item definition DB 42 defines an attribute of a record item. Definitions corresponding to all the object storage DBs 45 are stored. The DB 42 exists only one within the portable remote terminal 11 .
In the item definition DB 42 of FIG. 5, a DB name 42 - 1 represents a DB name of the object storage DB 45 . An item name 42 - 2 represents a record item name and corresponds to the columns 45 - 1 to 45 - 10 of the object storage DB 45 .
A data type 42 - 3 represents a data type of a record item and a control attribute. DT_TEXT denotes text edit, DT_MEMO denotes memory edit, DT_INT denotes integer edit, DT_ID denotes record ID edit, DT_CURRENCY denotes currency edit, DT_FLOAT denotes floating point edit, DT_BOOL denotes logical value check box, DT_DATE denotes date edit, DT_TIME denotes time edit, DT_TIMESTAMP denotes time stamp edit, DT_CHOICE denotes choice drop down list, DT_CMB denotes combo drop down (edit combo), DT_LINK denotes link field drop down list and DT_FLAG denotes flag edit.
A control attribute 42 - 4 represents a control attribute of a record item. Here, IP_HEADER denotes a record header (not displayed), IP_NORMAL denotes normal edit, IP_MUST denotes input must and IP_STATIC denotes edit disabled. An item width 42 - 5 represents a display size of a record item.
A reference DB name 42 - 6 represents a name of a DB to be referred to such as combo, choice and link.
Here, DT_CMB represents a name of the user's selection item DB 44 , DT_CHOICE represents a name of the user's selection item DB 44 and DT_LINK represents a name of the object storage DB 45 . A reference key 42 - 7 represents a key for use in obtaining a record from a reference DB. Here, DT_CMB denotes a key name of the user's selection item DB 44 , DT_CHOICE denotes a key name of the user's selection item DB 44 and DT_LINK denotes an item name of the object storage DB 45 .
A link destination item name 42 - 8 represents a correlated DT_LINK item name. A reference item name 42 - 9 represents a reference item name in a DB referred to by a DT_LINK item.
A list display order 42 - 10 represents the item display order selected in the list display, in which 0 denotes that no item is displayed and an integer not less than 1 indicates the display order number (integer). A card display order 42 - 11 represents the item display order selected in the card display, in which 0 denotes that no item is displayed and an integer not less than 1 indicates the display order number (integer).
A record index 42 - 12 represents an index to each column of a record of the object storage DB 45 in question. Index exists only for an item that a user has brought out. An updating flag 42 - 13 is a flag of a record to be updated which represents an object not to be synchronized as 0 and an object to be synchronized as 1.
(c) Relation Definition DB 43
The relation definition DB 43 defines relations such as detailed/link destination corresponding to the object storage DB 45 . Definitions corresponding to all the object storage DBs 45 are stored. The relation definition DB 43 exists only one within the portable remote terminal 11 .
A host DB name 43 - 1 represents a top-level object storage DB name which is a DB name of the object storage DB 45 as a host. A detailed DB name 43 - 2 denotes a second-level object storage DB name which is a detailed DB name that can be displayed with respect to the host object storage DB 45 . A link destination detailed DB item name 43 - 3 represents an item name of a detailed DB where a record ID of a host DB is stored.
(d) User's Selection Item DB 44
The user's selection item DB 44 defines the contents of a combo item and a choice item. The DB exists only one within the portable remote terminal 11 .
A key name 44 - 1 represents a key which identifies a record group. The key name is used in the reference key 42 - 7 of the item definition DB 42 . An item value 44 - 2 represents an item value within the group and corresponds to a record value in the choice item. An item contents 44 - 3 represents item contents which correspond to those in the combo item.
(e) Object Storage DB 45
The DBs exist in the plural within the portable remote terminal 11 . The DBs exist as many as the number of objects to be linked with the personal computer 10 .
A serial ID 45 - 1 represents a record ID in a data base on the side of the portable remote terminal 11 which is sequentially applied at the time of the synchronous processing. At the time of new addition, the ID is applied to the end as a serial number. At the time of deletion, the ID has a blank. A record ID 45 - 2 represents a record ID on the side of the personal computer 10 which is not changed on the side of the portable remote terminal 11 . A time stamp 45 - 3 represents a time stamp of a record on the side of the personal computer 10 . The time stamp is not changed on the side of the portable remote terminal 11 . At the time of new creation, the time stamp has a blank.
An updating flag 45 - 4 is a flag of a record to be updated which represents an object not to be synchronized as 0 and an object to be synchronized as 1. Items 45 - 5 to 45 - n represent record item contents values (n exist as many as the number of items which a user will bring out).
Next, initialization processing, downloading of host DB data, data editing on a portable remote terminal, synchronous processing of data and editing of a data display item in thus structured data link system of the present invention will be outlined with reference to the drawings.
(1) Initialization Processing
As the initialization processing, the application program A 21 of the personal computer 10 generates a DB set forth below as the setting of a DB link item. The following initialization processing is executed by user's instructions to the application program A 21 . FIG. 9 shows a flow chart of the initialization processing.
On the personal computer 10 , prepare a table of data which might be taken out into the portable remote terminal 11 and a table of field information and select business object data which will be taken out by a user and its record item based on the information (Step 901 ). The selection of business object data to be taken out and its record item is conducted by the user's operation of the application program A 21 .
Then, based on the information, create the item definition DB 42 which defines a record attribute (Step 902 ).
According to the contents of the created item definition DB 42 , create an individual object storage DB ( 45 a , 45 b , 45 c , . . . , 45 n ) region (Step 903 ).
Next, create the relation definition DB 43 which defines relations such as detailed/link destination corresponding to the created object storage DB ( 45 a , 45 b , 45 c , . . . , 45 n ) from the item definition DB 42 (Step 904 ).
Furthermore, when an alternative item data region exists within the object storage DB ( 45 a , 45 b , 45 c , 45 n ), create a region of the user's selection item DB 44 (Step 905 ). Each of the created DBs is managed by the data base definition DB 41 which is created for defining a relation of a DB every time the DB is created (Step 906 ).
Next, download the data of the host DB 22 into the portable remote terminal 11 (Step 907 ). Downloading of the data of the host DB 22 is conducted by the application program A 21 . On the basis of a record taken out from the host DB 22 and according to the contents of a record attribute of the item definition DB 42 , write data into the corresponding object storage DBs 45 a to 45 n (Step 907 ).
(2) Data Editing on the Portable Remote Terminal
Editing work of data taken in into the portable remote terminal 11 is conducted by the application program B 31 . FIGS. 12 and 13 each show a data editing screen on the portable remote terminal 11 .
In FIG. 12, displayed in the list are a company name 501 , a telephone number 502 and a facsimile (facsimile number) 503 .
In FIG. 13, displayed in the card are information regarding one of the companies listed in FIG. 12 (company name 601 , how to read 602 , address (metropolis/prefecture, city/ward) 603 , telephone number 604 , facsimile 605 , relation 606 ).
On the list display of FIG. 12, by pressing (double tap) down a line in which data of the company name 501 , the telephone number 502 and the facsimile 503 is displayed with the pen 13 as an input means of the portable remote terminal 11 , a selected record is displayed in the card to allow editing of each field.
(3) Synchronous Processing
The processing of synchronizing the host DB 22 of the personal computer 10 and the DB 40 of the portable remote terminal 11 is executed by the application program A 21 . Conducted here is reading the DB 40 on the portable remote terminal 11 by the personal computer 10 to write the data into the host DB 22 in the personal computer 10 . In other words, write a record newly added/updated into the host DB 22 . In addition, set a link field between tables to a correct record ID to solve link information. This synchronous processing is automatically executed by the application program A 21 upon connection of the portable remote terminal 11 to the personal computer 10 . The processing is also executed by an instruction from the portable remote terminal 11 .
In the following, the synchronous processing by the application program A 21 will be described with reference to the flow chart of FIG. 10 .
Solution of link data on the portable remote terminal 11 (Step 1001 ).
In the program of the application program B 31 of the portable remote terminal 11 , such link data solution processing as set forth below is conducted prior to the synchronous processing. This link data solution processing is automatically executed by the application program B 31 . The present processing is usually conducted also in the screen editing processing by the application program B 31 .
In the following, description will be made of solution of a link between records and reference to a record.
According to the data type 42 - 3 of the record 422 of the item definition DB 42 , an attribute of the item 5 ( 45 - 9 ) of the record 451 of the object storage DB 45 a (company) is a link field. In this case, since the reference DB name 42 - 6 indicates “product” to link with the object storage DB 45 b (product), according to the contents “1” of the item 5 ( 45 - 9 ) of the record 451 of the object storage DB 45 a (company), the record 452 of the object storage DB 45 b (product) whose serial ID is “1” is supposed to link with the record 452 . Furthermore, since the reference key 42 - 7 indicates “product name”, the contents of the item 1 ( 45 - 5 ) of the record 452 of the object storage DB 45 b (product) will be referred to by the record index 42 - 12 .
As to an attribute of the item 6 ( 45 - 10 ) of the record 451 of the object storage DB 45 a (company), according to the link destination item name 42 - 8 and the reference item name 42 - 9 of the record 423 of the item definition DB 42 , the contents of the reference item name 42 - 9 of the reference DB indicated by the link destination item name 42 - 8 will be referred to. With the link destination item name 42 - 8 indicating “line of trade”, a field of a link destination indicated by the reference DB name 42 - 6 (product) and the reference key 42 - 7 (product name) of the record 422 will be referred to. Also, since the item 5 ( 45 - 9 ) of the record 451 of the object storage DB 45 a (company) indicates “1”, price of the record 452 of the object storage DB 45 b (product) whose serial ID is “1” will be referred to and in the item 6 ( 45 - 10 ) of the record 451 of the object storage DB 45 a (company), “10000” is stored as real data.
As the premise for conducting synchronous processing, updating flag setting processing is conducted in screen editing processing by the application program B 31 . Updating flags exist in the data base definition DB 41 and the item definition DB 42 , and the object storage DB 45 . The DB updating flag 41 - 4 of the data base definition DB 41 is set up when updating or addition is made of the managed data base. The updating flag 42 - 13 of the item definition DB 42 is set up when the contents of the item width 42 - 5 , the list display order 42 - 10 and the card display order 42 - 11 are modified. The updating flag 45 - 4 of the object storage DB is set up when a record is updated.
Transfer only the modified data from the portable remote terminal 11 to the personal computer 10 (Step 1002 ).
An object storage DB corresponding to a record whose DB updating flag 41 - 4 in the data base definition DB 41 is changed to “1” is searched and only the searched object storage DB is regarded as a DB to be synchronized. In the case of the data base definition DB 41 shown in FIG. 4, since the DB updating flags 41 - 4 of the records 412 and 415 have “1”, they are regarded as DBs to be synchronized.
Of the DBs considered to be synchronized (item definition DB 42 , object storage DB 45 a (company)), only a record whose updating flag indicates “1” is transferred to the side of the personal computer 10 .
Merge at the personal computer 10 (Step 1003 ). DB on the side of the personal computer 10 is updated by the updated data which is transferred from the portable remote terminal 11 .
Transfer latest data to the portable remote terminal 11 (Step 1004 ). The personal computer 10 writes data updated later than the previous synchronization time over old data in the portable remote terminal 11 .
After the completion of the above-described transfer of the latest data, initialize a flag (Step 1005 ). The synchronization time and date 41 - 3 of the data base definition DB 41 is updated and the updating flags 41 - 4 , 42 - 13 and 45 - 4 of the data base definition DB 41 , the item definition DB 42 and the object storage DB 45 a (company) are initialized.
(4) Data Display Item Editing
A user selects and retains the order of data items to be displayed in data editing (display/input) on the portable remote terminal 11 .
Shown in FIG. 11 is a display screen 210 for making a user select the order of data items to be displayed in data editing (display/input) on the portable remote terminal 11 conducted by the application program B 31 illustrated in FIG. 3 .
DB data being read into the portable remote terminal 11 is displayed as record items within a window 221 at the left part of the screen. When there is one to be displayed among the items, selecting the item using the pen 13 as indicated by a highlight display example 242 leads to addition and deletion of display by arrow buttons 231 a and 231 b . In the example of FIG. 11, pressing the arrow button 231 a leads to addition of the item indicated by the highlighted display example 242 to a window 222 at the right part of the screen. A highlight display example ( 243 ) shows a state of an item being selected.
The order of displayed items can be changed by using arrow buttons 232 a and 232 b with respect to the highlight display example ( 243 ). Using the upward arrow 232 a makes the highlight display example ( 243 ) have an immediately preceding displayed item and using the downward arrow 232 b makes the highlight display example ( 243 ) have an immediately succeeding displayed item.
As described in the foregoing, the present embodiment enables the portable remote terminal 11 to arbitrarily take out a part of data items of the host DB 22 of the personal computer 10 and conduct data editing (display/modification/input). When a user brings out and uses the portable remote terminal 11 at his or her destination, therefore, effective use of data is possible.
As described in the foregoing, the system for linking data between a personal computer and a portable remote terminal of the present invention and the data linking method therefor attain the following effects.
First, the processing of taking in data from the personal computer into the portable remote terminal and the processing of synchronizing the portable remote terminal with the personal computer can be executed in a short time period because only the data that needs to be brought out from a data base of the computer by the portable remote terminal is selectable.
Secondly, quick application of data is enabled by selectively taking in data that needs to be brought out from a data base of the computer by the portable remote terminal.
Thirdly, since the order of displayed items or display/non-display of data brought out into the portable remote terminal can be changed by a user as required, efficient use of data is possible.
Although the invention has been illustrated and described with respect to exemplary embodiment thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without departing from the spirit and scope of the present invention. Therefore, the present invention should not be understood as limited to the specific embodiment set out above but to include all possible embodiments which can be embodies within a scope encompassed and equivalents thereof with respect to the feature set out in the appended claims.
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In a data linking method of extracting data of a host data base on a computer into a portable remote terminal, an item definition data base which defines a record attribute, an object storage data base which stores object data on a record basis, a relation definition data base which defines relations among object data and a definition data base which defines relations among the respective data bases, and conducts synchronous processing of writing. The portable remote terminal conducts link data solution processing based on a record attribute of the item definition data base when a record item of the object storage data base refers to other object storage data base, and changes, when the display order of object data of the object storage data base is changed or when existence/non-existence of display is selected, the display order of object data of said item definition data base or an attribute indicative of existence/non-existence of display according to the contents of the change or the selection, and the computer further reads an updated record from said object storage data base of the portable remote terminal to update the host data base.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY-SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to fingernail hygiene, and more particularly, but not by way of limitation, to an improved finger-nail instrument for manicuring and honing the underside of fingernails.
2. Description of Related Art
Nail files are commonly constructed with an abrasive surface for honing uneven or rough portions of the nail. These nail files are useful for quickly and easily trimming and filing the ends of the nail and for smoothing the upper surfaces.
Artificial and acrylic nails are popularly used as alternatives to natural nails. When applying acrylic nails, an artificial nail tip is bonded to the outer edge of the natural nail so that the artificial nail extends outwardly therefrom. Once the bonding material dries, liquid acrylic is applied to the upper exposed surface of the natural nail, as well as the artificial nail, creating a substantially elongated uniform upper nail surface. When the acrylic material hardens, the nail requires extensive filing to smooth uneven portions on the upper exposed nail surface and often the underside of the nail because of excess glue as well as an uneven binding.
Also, the underside of the nail often becomes rough, dirty, and discolored both where the artificial nail extends outwardly from the natural nail, as well as, under the natural nail itself. Therefore, the underside of the nail requires extensive filing and smoothing as well as periodic manicuring thereafter. Similar reasoning exists for manicuring the underside of natural nails.
Presently, most manicuring devices employ a standard emery board to hone and shape the exposed upper surfaces of natural and acrylic nails. Prior art devices capable of filing the fingernail are known in the art; however, these devices are not conducive to filing under the nail, are unable to clean or reach deep under the nail, and are inappropriately shaped to file the underside of the fingernail effectively.
Also, professional manicurists utilize motorized manicuring machines which employ grinding stones of specific design for reaching and honing the undernail area. However, these professional machines are expensive, cumbersome, and require a power-supply which makes remote transport and use impractical.
Accordingly, a need exists for an improved fingernail manicuring instrument for manicuring and honing the underside of fingernails which is readily portable, inexpensive, and capable of reaching deep within the undernail area. It is to such a fingernail manicuring instrument that the present invention is directed.
SUMMARY OF THE INVENTION
The present invention relates generally to an instrument for manicuring the underside of fingernails. It is to be understood that the term "fingernails" as used herein includes natural, artificial, and acrylic fingernails.
Broadly, the fingernail manicuring instrument of the present invention comprises a shaft member having a first end, a second end, and an abrasive member connected to at least one of the first and second ends of the shaft member. The abrasive member, which is sized and dimensioned so that at least a portion of the abrasive member is positionable adjacent a portion of the underside of a fingernail, is provided with an arcuate-shaped abrasive surface which substantially corresponds with at least a portion of the arcuate-shape of the underside of the fingernail. More specifically, the abrasive member is provided with a substantially elliptical cross-section and a pointed distal end so as to permit placement of the abrasive member underneath an outwardly extending portion of the fingernail and thereby permit abrasive engagement of the abrasive member with the underside of the fingernail to hone and file the underside of the fingernail.
In one embodiment, the fingernail manicuring instrument of the present invention comprises a first abrasive member connected to the first end of the shaft member and a second abrasive member connected to the second end of the shaft member. One of the first and second abrasive members is provided with a substantially teardrop shape having a substantially elliptical cross-sectional configuration, and the other of the first and second abrasive members is provided with a substantially conical shape having a substantially elliptical cross-sectional configuration.
An object of the present invention is to provide an improved instrument for manicuring and honing the underside of fingernails which is capable of reaching deep within the undernail area.
Another object of the present invention, while achieving the before-stated object, is to provide an improved instrument for manicuring and honing the underside of fingernails which is readily portable, inexpensive, and easy to use.
Other advantages and features of the present invention will become apparent to those skilled in the art from the following detailed description when read in conjunction with the drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial representation of a fingernail manicuring instrument of the present invention illustrating the positioning of an abrasive member thereof underneath a fingernail for filing and honing the underside of the fingernail.
FIG. 2 is a top plan view of the fingernail manicuring instrument of the present invention.
FIG. 3 is a side elevational view of the fingernail manicuring instrument of the present invention.
FIG. 4 is a cross-sectional view of a first abrasive member of the fingernail manicuring instrument of FIG. 3 taken along 4--4 thereof.
FIG. 5 is a cross-sectional view of the first abrasive member of the fingernail manicuring instrument of FIG. 3 taken along 5--5 thereof.
FIG. 6 is a cross-sectional view of the first abrasive member of the fingernail manicuring instrument of FIG. 3 taken along 6--6 thereof.
FIG. 7 is a cross-sectional view of a second abrasive member of the fingernail manicuring instrument of FIG. 3 taken along 7--7 thereof.
FIG. 8 is a cross-sectional view of the second abrasive member of the fingernail manicuring instrument of FIG. 3 taken along 8--8 thereof.
FIG. 9 is a cross-sectional view of the second abrasive member of the fingernail manicuring instrument of FIG. 3 taken along 9--9 thereof.
DETAILED DESCRIPTION
Referring now to the drawings, and in particular to FIG. 1, shown therein is a fingernail manicuring instrument 10 constructed in accordance with the present invention. The fingernail manicuring instrument 10 comprises a shaft member 12 having a first end 14, a second end 16 (FIGS. 2 and 3) and an outer peripheral surface 18. The shaft member 12, which is substantially rigid, can be constructed of any material, such as wood, metal, polymeric materials, ceramic materials, porcelain materials, and the like.
The shaft member 12 is illustrated as an elongated member having a generally cylindrical cross-sectional configuration. However, it should be understood that the shaft member 12 may have any desired cross-sectional configuration, such as oval, square, or any other such configurations provided the shaft member 12 is easily graspable by a person, such as by a person's hand 20 as illustrated in FIG. 1. That is, the outer peripheral surface 18 of the shaft member 12 is desirably provided with a comfortable surface for grasping and manipulating the fingernail manicuring instrument 10 by the person's hand 20.
Referring now to FIGS. 2 and 3, in combination with FIG. 1, the fingernail manicuring instrument 10 further comprises a first abrasive member 22 connected to the first end 14 of the shaft member 12 and a second abrasive member 24 connected to the second end 16 of the shaft member 12. The first abrasive member 22, which is sized and dimensioned so that at least a portion of the first abrasive member is positionable adjacent a portion of the underside 26 of a fingernail 28 substantially as shown in FIG. 1, is provided with an arcuate-shaped abrasive surface 30 which substantially corresponds with at least a portion of the arcuate-shape of the underside 26 of the fingernail 28.
Thus, the first abrasive member 22 has a substantially elliptical cross-section so as to permit placement of the first abrasive member 22 underneath an outwardly extending portion of the fingernail 28. The configuration of the first abrasive member 22 thus permits at least a portion of the first abrasive member 22 to abrasively engage and manicure (i.e. hone and file) the underside 26 of the fingernail 28 in response to movement of the shaft member 12 imparted upon the shaft member 12 by the person's hand 20. That is, filing and honing of the underside 26 of the fingernail 28 can be maximized by imparting either a vertical movement, or a circular movement indicated by the arrow 32 upon the shaft member 12 (FIG. 1), or by imparting a horizontal movement indicated by the arrow 33 relative to the fingernail 28 upon the shaft member 12 (FIG. 1), or by a combination of circular movement, horizontal movement, and/or vertical movement, or any other movement capable of imparting a filing and honing action to the underside 26 of the fingernail 28.
Referring more specifically to FIGS. 2 and 3, the first abrasive member 22, which is illustrated as having a substantially teardrop configuration, is further characterized as having a base portion 34, a distal end 36, an outer peripheral surface 38 and a substantially elliptical crosssection (FIG. 6), the purpose of which will be described in more detail hereinafter.
The first abrasive member 22 is connected to the first end 14 of the shaft member 12 with a bonding material so as to permanently attach the first abrasive member 22 to the first end 14 of the shaft member 12. The bonding material may be any of a variety of commercially available bonding materials capable of bondingly connecting the first abrasive member 22 to the first end 14 of the shaft member 12 so as to provide a permanent bond therebetween.
Alternatively, the first abrasive member 22 may have a female portion which matingly receives a male portion. The first end 14 of the shaft member 12 includes a male portion which in combination with bonding material bondingly attaches the first abrasive member 22 with the shaft member 12. It should also be understood that the first abrasive member 22 may be integrally formed from a portion of the shaft member 12. In such construction, the first abrasive member 22 may be formed from the first end 14 of the shaft member 12 such that the first abrasive member 22 is of substantially tear drop configuration. Other configurations for permanently attaching the first abrasive member 22 to the first end 14 of the shaft member 12 may be employed for the present purposes.
The first abrasive member 22 is provided with the outer peripheral surface 38 having an abrasive material 40 disposed thereon. The abrasive material 40, such as emery or other material of an abrasive composition, is bondingly disposed on the outer peripheral surface 38 of the first abrasive member 22. The abrasive material 40 may comprise fine, medium, or coarse emery granules such as sand or other abrasive compounds which may be fixed to the outer peripheral surface 38.
The first abrasive member 22 may also be formed of a substantially uniform and solid abrasive material. In such construction, the first abrasive member 22 is formed of a substantially uniform abrasive material such that the substantially uniform abrasive material may comprise varying grades of coarseness.
The second abrasive member 24 of substantially conical configuration is connected to the second end 16 of the shaft member 12. The second abrasive member 24 has a base portion 52, a distal end 54, and an outer peripheral surface 56. The second abrasive member 24 has a substantially elliptical cross-sectional configuration which will be further described hereinafter.
The second abrasive member 24 is connected to the second end 16 of the shaft member 12 with a bonding material so as to permanently attach the second abrasive member 24 to the second end 16 of the shaft member 12. The bonding material may be any of a variety of commercially available bonding materials capable of bondingly connecting the second abrasive member 24 to the second end 16 of the shaft member 12 so as to provide a permanent bond therebetween.
Alternatively, the second abrasive member 24 may have a female portion which matingly receives a male portion. The second end 16 of the shaft member 12 includes a male portion which in combination with bonding material bondingly attaches the second abrasive member 24 with the shaft member 12. It should also be understood that the second abrasive member 24 may be integrally formed from a portion of the shaft member 12. In such construction, the second abrasive member 24 may be formed from the second end 16 of the shaft member 12 such that the second abrasive member 24 is of substantially conical configuration. Other configurations for permanently attaching the second abrasive member 24 to the second end 16 of the shaft member 12 may be employed for the present purposes.
The second abrasive member 24 is provided with an outer peripheral surface 56 having an abrasive material 58 disposed thereon. The abrasive material 58, such as emery or other material of an abrasive composition, is bondingly disposed on the outer peripheral surface 56 of the second abrasive member 24. The abrasive material 58 may comprise fine, medium, or coarse emery granules such as sand or other abrasive compounds which may be fixed to the outer peripheral surface 56.
The second abrasive member 24 may be formed of a substantially uniform and solid abrasive material. In such construction, the second abrasive member 24 is formed of a substantially uniform abrasive material such that the substantially uniform abrasive material may comprise varying grades of coarseness.
Referring now to FIG. 3, it can be seen that the first abrasive member 22 and the second abrasive member 24 are both of substantially elliptical cross-sectional configuration. The first abrasive member 22 is of substantially tear drop configuration and is provided with an upper side 60 and a lower side 62. The first abrasive member 22 is shown having a curvature along the upper side 60 whereby the base portion 34 is raised relative to the distal end 36. This curved design along the upper side 60 of the first abrasive member 22 is provided to conform to the underside 26 of the fingernail 28 such that abrasive material 40 applied to the outer peripheral surface 38 formingly contacts the contoured undernail area.
Thus, it can be appreciated that the substantially tear drop configuration of the first abrasive member 22 promotes contact of the undernail with the maximum surface area of the abrasive material 40 disposed on the outer peripheral surface 38 for manicuring the undernail area. Due to the symmetrical nature of the upper side 60 with respect to the lower side 62 of the first abrasive member 22, the tear drop configuration allows the distal end 36 of the first abrasive member 22 to extend a maximum distance into the undernail area since the lower side 62 of the distal end 36 is similarly curved and therefore produces a low profile. The low profile of the distal end 36 allows optimum reach into the undernail area without the reach being impeded by the tip of the finger which provides for the maximum penetration into the depth of the undernail area (FIG. 4).
Such construction of the distal end 36 produces improved undernail honing and manicuring since the distal end 36 continues to promote contact of the abrasive material 40 applied on the outer peripheral surface 38 with the underside 26 of the fingernail 28. However, the base portion 34 of the upper side 60 is shown to be more elliptically rounded (FIGS. 5 and 6) as the base portion 34 extends nearer the first end 14 of the shaft member 12 where the first abrasive member 22 is connected to the shaft member 12. The increasing curvature arc of the rounded outer peripheral surface 38 of the first abrasive member 22 at the base portion 34 promotes contact of the abrasive material 40 the outer peripheral surface 38 for abrading engagement with similar arcuate curvature of the underside 26 of the fingernail 28.
Thus, it can be seen that the gradual shallowing of the elliptical cross-section of the first abrasive member 22 as it extends from its most rounded configuration near the base portion 34 (FIG. 6) to its most elliptically shallow arc nearest the distal end 36 (FIG. 4) increases the versatility of the first abrasive member 22 for both reaching the depths of the undernail area and promoting forming contact of the first abrasive member 22 with the underside 26 of the fingernail 28 for honing and manicuring purposes.
The second abrasive member 24 is substantially conically-shaped and is provided with an upper side 64 and a lower side 66. The second abrasive member 24 is shown having a curvature along the outer peripheral surface 56, along the upper side 64 whereby the base portion 52 is raised relative to the distal end 54. This curved design along the upper side 64 of the second abrasive member 24 is provided to conform with the underside 26 of the fingernail 28, such that the abrasive material 58 applied thereon to the outer peripheral surface 56 formingly contacts the contoured undernail area.
Thus, it can be appreciated that the substantially conical configuration of the second abrasive member 24 promotes contact of the undernail with the maximum surface area of the outer peripheral surface 56, causing the abrasive material 58 disposed thereon to abradingly engage the undernail area. Due to the symmetrical nature of the upper side 64 with respect to the lower side 66 of the second abrasive member 24, the conical configuration allows the distal end 54 of the second abrasive member 24 to extend the maximum distance into the undernail area, since the lower side 66 of the distal end 54 is similarly curved and therefore produces a low profile. The low profile of the distal end 54 allows optimum reach into the undernail area without the reach being impeded by the tip of the finger.
It can be seen that the conical configuration of the distal end 54 of the second abrasive member 24 maintains a substantially elliptical cross-sectional configuration (FIG. 7). Such construction of the distal end 54 produces improved undernail honing and manicuring since the distal end 54 continues to promote contact of the abrasive material 58 applied on the outer peripheral surface 56 with the underside 26 of the fingernail 28. However, the base portion 52 of the upper side 64 is shown to be more elliptically rounded (FIGS. 8 and 9), as the base portion 52 extends nearer the second end 16 of the shaft member 12 where the second abrasive member 24 is connected to the shaft member 12. The increasing curvature arc of the rounded outer peripheral surface 56 of the second abrasive member 24 near the base portion 52 promotes contact of the abrasive material 58 disposed on the outer peripheral surface 56 for abrading engagement with the similar arcuate curvature of the underside 26 of the fingernail 28.
It can be seen that the gradual shallowing of the elliptical cross-section of the second abrasive member 24 as it extends from the most rounded configuration near the base portion 52 (FIG. 9) to its most elliptically shallow arc nearest the distal end 54 (FIG. 7) increases the versatility of the second abrasive member 24 for both reaching the depths of the undernail area and promoting forming contact of the second abrasive member 24 with the underside 26 of the fingernail 28 for honing and manicuring purposes.
In another aspect, the abrasive material 40 disposed on the outer peripheral surface 38 of the first abrasive member 22 may be more coarse with larger abrasive particles relative to the less coarse abrasive material 58 disposed on the outer peripheral surface 56 of the second abrasive member 24. In another aspect, the abrasive material 40 disposed on the outer peripheral surface 38 of the first abrasive member 22 may be less coarse with smaller abrasive particles relative to the more coarse abrasive material 58 disposed on the outer peripheral surface 56 of the second abrasive member 24. In another aspect, the abrasive material 40 disposed on the outer peripheral surface 38 of the first abrasive member 22 may be of similar coarseness relative to the abrasive material 40 disposed on the outer peripheral surface 56 of the second abrasive member 24.
In manicuring the underside 26 of the fingernail 28, the manicuring instrument 10 is positioned underneath an outwardly extending portion of the fingernail 28. Upon movement of the shaft member 12, the first abrasive member 22 abrasively engages the underside 26 of the fingernail 28 to hone and file the underside 26 of the fingernail 28. The manicuring instrument 10 is positioned such that either the first abrasive member 22 or second abrasive member 24 is placed adjacent the underside 26 of the fingernail 28 such that either the first abrasive member 22 abradingly engages the underside 26 of the fingernail 28. Thereafter, a movement must be imparted to the shaft member 12, causing the first abrasive member 22 to engage the underside 26 of the fingernail 28, thereby providing an abrasive action on the underside 26 of the fingernail 28.
The filing and honing of the underside 26 of the fingernail 28 is maximized by imparting the circular movement indicated by the arrow 32 upon the shaft member 12. Such circular movement causing the outer peripheral surface 38 of the first abrasive member 22 to abradingly engage the underside 26 of the fingernail 28. The circular movement allows the substantially arcuate shaped first abrasive member 22 to conform to the arcuate shaped underside 26 of the fingernail 28.
By imparting vertical movement and/or horizontal movement indicated by the arrow 33 relative to the fingernail 28 upon the shaft member 12, the second abrasive member 24 may be caused to reach the depths of the undernail area. Such vertical movement and/or horizonal movement imparted upon the shaft member 12 causes the outer peripheral surface 56 of the second abrasive member 24 to abradingly engage deep under the fingernail 28 for filing and honing. The manicuring instrument 10 can then be removed so that the first abrasive members 22 is no longer in contact with the underside 26 of the fingernail 28.
From the above description, it is clear that the present invention is well adapted to carry out the objects, and obtain the advantages mentioned herein, as well as those inherent in the invention. While a presently preferred embodiment of the invention has been described for the purposes of this disclosure, it will be understood that numerous changes may be made which will readily suggest themselves to those skilled in the art and which are accomplished within the spirit of the invention disclosed and as defined in the appended claims.
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An instrument and method for manicuring the underside of natural, artificial and acrylic fingernails. The instrument comprises a shaft member having a first end and a second end, and an abrasive member connected to at least one of the first and second ends of the shaft member. The abrasive member having a substantially arcuate shaped abrading surface for permitting at least a portion of the abrasive member to be positioned for abrading engagement with the underside of the fingernail to file and hone the underside of the nail.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] None
FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0003] Not Applicable
STATEMENT REGARDING COPYRIGHTED MATERIAL
[0004] Portions of the disclosure of this patent document contain material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND
[0005] The present invention relates in general to garment hangers, and more particularly to a retractable multi-tiered hanger for holding multiple lingerie.
[0006] Garment hangers are used to conveniently store and organize garments, and a variety of garment hangers have been developed in the art. These hangers generally include a hook and a main body connected to the hook. Some of these hangers are designed for supporting a single garment while others support multiple garments. For example, U.S. Pat. No. 2,514,742 to Burger discloses a multiple garment hanger, which comprises a flat base member and a hook member connected to an upper terminal of the flat base member. The side and bottom edges of the flat base member include a plurality of projections having slots or notches. The slots are spaced parallel to the longitudinal axis of the hanger. The garments are hung in a stepped fashion inwardly and downwardly towards the hanger body.
[0007] U.S. Pat. No. 5,582,334 to Blazer discloses a multi-garment, insect infestation inhibiting hanger device for use on a clothes bar. The device comprises a main body that is engaged to a hook. The main body is formed from a section of cut incense cedar or other similarly suitable moth and other insect inhibiting wood. The main body includes a downwardly and inwardly tapering main section and a plurality of garment receiving structures with slots. The device is configured to receive either a plurality of hangers or garment hanging loops.
[0008] U.S. Pat. No. 2,469,481 to Snyder discloses a garment hanger, which comprises a supporting member, a pair of spaced side pieces mounted on the opposite sides of the supporting member and clamping members carried by the side pieces. The side pieces decrease in width from top to bottom to provide inwardly offset edge portions, each carrying two clamps. Spring members are used to achieve clamping action.
[0009] Although the above hangers are designed to support multiple garments, they differ from the multi-tiered structure of the present invention, which is specifically designed for lingerie.
[0010] U.S. Pat. No. 6,070,773 to Pogoda discloses a lingerie hanger comprising a vertical rod, a hook disposed on top of the vertical rod and a plurality of horizontal crossbars attached to the vertical rod along its length. Both the ends of each horizontal crossbar are curved upwards a short distance and back a longer distance toward the vertical rod. Although this lingerie hanger comprises a multi-tiered structure, the present invention improves the art, providing a three-dimensional multi-tiered hanger specially designed to hang and organize lingerie and other undergarments.
[0011] Lingerie and other garments are frequently stored in drawers, where they are arranged in piles. It is difficult to find a particular undergarment in a pile of lingerie stored in the drawer. In addition, the types of fabric used to make most lingerie makes it difficult to fold and store. Therefore, it is an object of the present invention to provide a hanger that is specially designed for lingerie.
[0012] A further object is to provide a lingerie hanger that comprises a three-dimensional multi-tiered structure.
[0013] A further object is to provide a lingerie hanger that can accommodate multiple undergarments.
[0014] A further object is to provide a lingerie hanger that can be retracted for storage.
[0015] A further object is to provide a lingerie hanger that can be rotated about a vertical axis which makes it easy to place as well as retrieve the undergarments.
[0016] Finally, it is an object of the present invention to provide a lingerie hanger that is convenient to store and retrieve lingerie and can be hung in a closet or a wardrobe to a clothes bar. These and other objects of the present invention will become better understood with reference to the appended Summary, Description, and Claims.
SUMMARY
[0017] The present invention is a retractable multi-tiered multiple lingerie hanger. The hanger is a three-dimensional structure comprising a hook and two frames. Each frame is defined by a pair of telescopically-retractable vertical tubes connected by a plurality of horizontal bars. The vertical tubes enable the hanger to retract vertically when not in use. Each horizontal bar includes a plurality of upward projections adapted to receive lingerie. The front and rear frames are connected by a plurality of connecting members to form a substantially cuboidal structure. The hook is located above and at the central point between the first and second frames. The hook can also be collapsed downward when not in use.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1 is a perspective view of the retractable multi-tiered lingerie hanger in accordance with the present invention.
[0019] FIG. 2 is a front view of the lingerie hanger in accordance with the present invention.
[0020] FIG. 3 is a top view of the lingerie hanger in accordance with the present invention.
[0021] FIG. 4 is a perspective view of the lingerie hanger with the frames collapsed in accordance with the present invention.
[0022] FIG. 5 is a perspective view of the horizontal member in accordance with the present invention.
[0023] FIG. 6 is a perspective view depicting the hook and the horizontal member connected together in accordance with the present invention.
[0024] FIG. 7 is a perspective view of the lingerie hanger in totally collapsed position in accordance with the present invention.
[0025] FIG. 8 is a perspective view of the hook in accordance with the present invention.
[0026] FIG. 9 is a perspective view of the lingerie hanger hooked onto a clothes bar in accordance with the present invention.
FIGURES—REFERENCE NUMERALS
[0000]
10 . . . Retractable Multi-tiered Lingerie Hanger
12 . . . Collapsible Hook
14 . . . Frame
16 . . . First Telescopically-retractable Vertical Tube
18 . . . Second Telescopic-retractable Vertical Tube
20 . . . Horizontal Bar
22 . . . Upward Projection
24 . . . Connecting Bar
26 . . . Horizontal Member
28 . . . Connecting Member
30 . . . End Portion
32 . . . Central Portion
34 . . . Tubular Member
36 . . . Vertical Axis
38 . . . Clothes Bar
DETAILED DESCRIPTION
[0042] Referring to the drawings, the preferred embodiment of a retractable multi-tiered lingerie hanger is illustrated and generally indicated as 10 in FIGS.1 through 9 . The hanger 10 is a three dimensional structure comprising a collapsible hook 12 and two identical frames 14 , namely, a first and second, both connected together by maintaining a parallel and spaced apart relationship.
[0043] Referring to FIGS. 1 through 4 , each frame 14 is defined by a first telescopically-retractable vertical tube 16 , a second telescopically-retractable vertical tube 18 and a plurality of horizontal bars 20 connecting the first and second vertical tubes 16 & 18 . Each horizontal bar 20 includes a plurality of upward projections 22 , each adapted to receive lingerie. The upward projections 22 are covered with soft materials such as velvet. The horizontal bars 20 connecting the bottom ends of the vertical tubes 16 & 18 and may include upward projections 22 . The ends of the first vertical tubes 16 and the ends of the second vertical tubes 18 of the first and second frames 14 are connected by four connecting bars 24 , forming a substantially cuboidal structure. When not in use, the tubes 16 & 18 enable the hanger 10 to be telescopically collapsed for easy storage purposes.
[0044] Again referring to FIG. 1 , the hook 10 is connected to a horizontal member 26 , which in turn is connected to the top ends of the vertical tubes 16 .& 18 by four connecting members 28 . The horizontal member 26 , which is of a circular cross-section, is located above the first and second frames 14 , and at the central point between the first and second frames 14 . The connecting members 28 are slanted downwardly from the extremities of the horizontal member 26 toward the top ends of the vertical tubes 16 & 18 .
[0045] Referring to FIG. 5 , the horizontal member 26 can be divided into two end portions 30 and a central portion 32 ; the three portions 30 & 32 being coaxial. The central portion 32 of the horizontal member 26 has a cross-sectional area lesser than that of the end portions 30 .
[0046] Referring to FIGS. 5 through 7 , the bottom of the hook 12 is perpendicularly attached to a tubular member 34 , which is adapted to receive the central portion 32 of the horizontal member 26 . When the central portion 32 is received, the surface of the tubular member 34 becomes flush with the surface of the end portions 30 of the horizontal member 26 . This configuration enables the hook 12 to collapse downwardly when not being used as seen in FIG. 7 .
[0047] Referring to FIGS. 8 and 9 , the hook 12 is configured such that it can rotate about a vertical axis 36 , thus enabling the hanger 10 to rotate when hooked onto a rod or a clothes bar 38 . This arrangement of the hook 12 makes it easy to retrieve the lingerie that is hooked on the backside frame 14 just by rotating the hanger 10 .
[0048] All features disclosed in this specification, including any accompanying claims, abstract, and drawings, may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
[0049] Any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function, is not to be interpreted as a “means” or “step” clause as specified in 35 U.S.C. §112, paragraph 6. In particular, the use of “step of” in the claims herein is not intended to invoke the provisions of 35 U.S.C. §112, paragraph 6.
[0050] Although preferred embodiments of the present invention have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
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A multi-tiered hanger for holding multiple undergarments or lingerie. The hanger comprises at least two frames connected together to form a three-dimensional structure, and a hook about which the three-dimensional structure is supported. Each of the at least two frames comprises a means for receiving multiple lingerie.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an adjustable stabilizer bar for a vehicle.
2. Description of Related Art
Torsional stabilizer bars have proven useful in vehicles for many years. Such stabilizer bars commonly employ a transverse torsion bar segment pivotally attached to the vehicle chassis and leading or trailing longitudinal segements attached to a control arm or wheel carrier. Examples of stabilizer bars having this particular configuration are shown in U.S. Pat. Nos. 2,660,449, 3,181,885, 3,733,087, 4,066,278, and 4,143,887. These stabilizers act in a manner such that when a pair of left and right wheels differ in level from each other due to a cornering maneuver. the vehicle body will be prevented from excessive rolling or leaning to either side by the torsional resistance produced in the stabilizer bar.
In response to the driving public's demand for more "sporty" cornering capability, automotive designers have increased the diameters of conventional stabilizer bars. Although this modification beneficially increases roll stiffness, it also degrades ride quality in many cases. This results because the stabilizer couples the wheels together. For example, when one wheel strikes a raised obstruction in the roadway during straight running, the body will tend to roll more when a stronger or stiffer stabilizer is used than when a bar of lesser torsional stiffness is fitted.
Designers have sought to enhance the function of stabilizer bars in a variety of ways. U.S. Pat. No. 4,206,935 discloses a non-adjustable stabilizer bar with two halves which may be selectively coupled or entirely decoupled by means of a clutch mechanism. This stabilizer cannot produce varied degrees of stabilization. U.S. Pat. No. 3,197,233 discloses an active stabilizer system in which a bifurcated stabilizer bar is loaded torsionally by a hydraulic motor joining the two furcations. This system is limited because it requires an external pump driven by the vehicle's engine. It is further limited because torsional bias can be applied only when the vehicle is in a leaning situation; application of the bias when the vehicle is operating in a straight-ahead mode will cause the body to roll to one side. This necessarily limits the flexibility of the control strategy of the device.
U.S. Pat. No. 3,292,918 discloses a variable rate stabilizing assembly comprising a transversely mounted multipiece leaf spring coupled at its ends to the swing axle of an independent rear suspension. The roll stiffness produced by this system is not adjustable while the vehicle is in motion.
U.S. Pat. No. 3,490,786 discloses a variable action anti-roll mechanism in which a longitudinal segment of a stabilizer bar is selectively coupled to a transversely running torsional reaction segment. The stabilization capability of this system is limited by the stiffness of the simple transverse torsional reaction segment.
U.S. Pat. No. 3,589,700 discloses a flexibility corrector for a vehicle suspension system in which a resilient member mounted to a stabilizer bar alters the suspension spring rate when the wheels of the suspension move into jounce or rebound positions. U.S. Pat. No. 3,337,236 discloses a suspension having variable rate torsion bar springs but no stabilizer feature. Finally, German Auslegeschrift No. 1,160,313 discloses an adjustable torsion bar suspension including ride height control.
It is an object of the present invention to provide an adjustable stabilizer bar which does not require an engine driven pump and which permits either the driver or an automatic system to select the desired stiffness of the torsional reaction segment of the stabilizer bar. This allows a less powerful stabilizer bar to be employed in the normal course of events while permitting a stiffer bar to be used according to the driver's wishes or the dictates of the road.
SUMMARY OF THE INVENTION
According to the present invention, an adjustable stabilizer bar for a vehicle having multiple road wheels comprises a primary torsional reaction segment, means for operatively connecting the primary reaction segment with the suspension of the vehicle's road wheels such that the primary reaction segment will be torsionally loaded during jounce and rebound motion of the road wheels, and means for selectively modifying the torque reactive capacity of the primary reaction segment. More particularly, one or more secondary torsional reaction segments is provided with associated means for selectively adding the torque reaction capacity of each secondary segment to the torque reaction capacity of the primary segment. The means for selectively adding the reaction capacity of the secondary segments to that of the primary segment comprises means for interconnecting the secondary and primary segments which may, for example, comprise a clutch system adapted to prevent the various segments from rotating with respect to each other when the clutch is engaged. The clutch mechanism is responsive to either manual or automatic control means or both. The selectively employable secondary reaction segments permit the stabilizer bar to function as a small-diameter bar when road conditions or driving maneuvers dictate this modality, while providing a more powerful stabilizer in response to yet other road conditions of driving modes.
The adjustable stabilizer bar of the present invention is compatible for use with either manual or automatic control means. Automatic control means could include, for example, the sensing of lateral acceleration during cornering maneuvers. An example of such sensing used in combination with a vehicle leveling system is shown in U.S. Pat. No. 3,608,925.
The stabilizer bar of the present invention provides for adjustable multi-rate stabilization. The rate selection may be performed by either the driver or by an automatic control system which may sense vehicle velocity, lateral acceleration or any other suitable operating variable. This stabilizer bar is of simple construction and has built-in "limp home" capability inasmuch as even were the operating mechanism of the bar to fail, the stabilization force produced by the torsional reaction segment will remain constant at one of the system's selected values.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an adjustable stabilizer bar according to the present invention showing the stabilizer bar attached to a vehicle axle.
FIG. 2 is an enlarged view of a suitable clutch mechanism of the stabilizer bar showing the clutch in the disengaged position.
FIG. 3 is an enlarged view similar to FIG. 2 showing the clutch in the engaged position.
DESCRIPTION OF PREFERRED EMBODIMENT
In a preferred embodiment shown in FIG. 1, primary torsional reaction segment 4 is comprised of a bar pivoted to the chassis by means of isolating mounts 26a and 26b which are bracketed to the chassis by means of brackets 24a and 24b. Primary torsional reaction segment 4 may have a circular or an annular cross section or any other cross section known to those skilled in the art.
Primary torsional reaction segment 4 is unitary with longitudinal legs 20a and 20b which serve to attach primary reaction segment 4 to axle assembly 2. Longitudinal legs 20a and 20b are pivoted to axle assembly 2 at pivots 22a and 22b. Those skilled in the art will appreciate that longitudinal legs 20a and 20b need not be unitary with primary torsional reaction segment 4 and could, for example, comprise linkages of various types known to those skilled in the art.
Although the configuration shown in FIG. 1 is that of a conventional beam-type rear axle of a rear drive automobile, the stabilizer bar of the present invention can be used with a front or rear suspension having either independent or beam-type construction. Further, the stabilizer bar of the present invention is suitable for use either leading or trailing wheels to which it is connected. In any event, the stabilizer bar will incorporate means for communicating the torsional reaction segment with part of a road wheel suspension subject to displacement during jounce and/or rebound movement of the vehicle's road wheels.
As shown in each of the Figures, the stabilizer bar of the present invention also includes means for selectively modifying the torque reactive capacity of the primary reaction segment. This means includes one or more secondary torsional reaction segments and associated means for selectively adding the torque reaction capacity of one or more of said secondary reaction segments to the torque reaction capacity of the primary segment. For example, the preferred embodiment shown in the Figures includes a secondary torsional reaction segment comprising a bifurcated tubular member 6 and a clutch for selectively coupling the coadjacent ends of the bifurcated tubular member. Although a bifurcated tubular member is shown, those skilled in the art will appreciate that multiple tubular members could be used to produce a cascaded increase in torsional stiffness of the primary torsional reaction segment.
Bifurcated tubular member 6 is coaxial with as well as coextensive with a substantial portion of primary reaction segment 4. Tubular member 6 is welded at its distal or nonadjacent ends to the primary reaction segment. Because tubular member 6 has an inside diameter sized to be a slip fit on the outside diameter of the primary reaction segment, operation of the stabilizer bar with the clutch mechanism disengaged will be characterized by a torsional reaction identical to that reaction which would be produced were the primary torsional reaction segment to exist without the tubular member and clutch. Engagement of the clutch mechanism produces a torsionally stiffer stabilizer bar by adding the torque reactive capacity of the much heavier tubular secondary reactive member to that of the primary reaction segment.
Those skilled in the art will appreciate that the torsional reaction segments may be constructed of any suitable material such as various ferrous or non-ferrous metals, or non-metallic materials such as fiber reinforced plastic composites.
As shown with particularity in FIGS. 2 and 3, the clutch mechanism preferably comprises a plurality of dogs 10a and 10b mounted to the two halves of the bifurcated tubular member, and sliding clutch sleeve 8 which is piloted upon the outside diameter of tubular member 6 and driven by motor 16 by means of pushrod 14 and attaching lug 12. Motor 16 may be driven by any one of several well known mechanisms such as an electrical solenoid shown in FIG. 1 or by any of the several hydraulic or pneumatic devices familiar to those skilled in the art. Motor 16 is double acting so that sliding clutch sleeve 8 may be both engaged as shown in FIG. 3, or disengaged, as shown in FIG. 2, by motor 16. Those skilled in the art will appreciated that many alternative clutch arrangements may be used with the present invention inasmuch as the clutch functions to simply innerconnect the primary and secondary reactive segments and thus to prevent the various segments from rotating with respect to each other when the torsional reaction segment is subjected to torque loads. For example, the clutch could be interposed between one end of a unitary tubular member and the primary reaction segment.
Controller 28 preferably embodies both manual and automatic control capabilities. Manual control permits the operator of the vehicle to selectively employ the secondary torsional reaction system. The driver's choice to employ this system can be made on the basis of road conditions or to suit has taste regarding the road stiffness desired for his vehicle. The vehicle operator may select the desired mode by positioning an instrument panel switch in the appropriate position. This will energize the solenoid or fluid motor to shift the sliding clutch in the chosen position.
Automatic operation of the controller would preferably be based upon the sensing by the controller, or by associated sensors, of such parameters as vehicle speed or lateral acceleration encountered during turning maneuvers. The controller may thus be used to adapt the roll stiffness of the suspension system to the dictates of the road surface and the driver.
When used herein, the term "chassis" means conventional automotive chassis as well as conventional unitized automotive body structures.
Variations and modifications of the present invention are possible without departing from the spirit and scope of the invention as defined by the appended claims.
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An adjustable stabilizer bar for a vehicle comprises a primary torsional reaction segment, means for operatively connecting the primary reaction segment with the suspension of vehicle roadwheels such that the primary reaction segment will be torsionally loaded during jounce and rebound motion of the roadwheels, and means for selectively modifying the torque reactive capacity of the primary reaction segment. The torque reactive capacity of the primary reaction segment may be modified in response to manual or automatic controls.
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BACKGROUND OF THE INVENTION
The present invention relates to a device for transporting, positioning and adjusting of sectional reinforcement members for tack welding or the like in the assembly of panel plates or the like. It includes a plurality of gripping means for the sectional reinforcement member, a plurality of lifting magnets for the panel plate and a plurality of jack means for pressing the sectional member against the panel plate during the tack welding or the like.
A device of this type is described in the copending U.S. Patent application Ser. No. 850,265 filed Nov. 10, 1977, now U.S. Pat. No. 4,169,977 granted Oct. 2, 1979. In this device the lifting magnets for the panel plate and the jack means for pressing the sectional member against the panel plate are arranged on a jig which is movable along a yoke which itself is supported in a gantry which is movable on rails which extend transversally of the longitudinal direction of the gantry. The yoke can only be moved a limited amount with respect to the gantry and the device may therefore only be used for sectional members which are to be oriented generally parallel to the gantry. The ends of the yoke can be moved only a limited amount with resect to each other in the vertical direction and the device may therefore not be used where the panel plate slopes with respect to the longitudinal direction of the gantry. Furthermore, the yoke is straight and relatively long, resulting in that it cannot be used for panel plates for smaller vessels, bow and stern sections and vessels having particularly fine lines where a large part of the sections have a certain curvature. In addition, the cost of said device makes it difficult to obtain the necessary economic return in smaller shipyards.
BRIEF DESCRIPTION OF THE INVENTION
The object of the present invention is to overcome said drawbacks and deficiencies of the previously known devices. According to the invention this is accomplished by means of a device of the type mentioned in which the gripping means, the lifting magnets and the yoke means are arranged on a boom means, with the boom means being equipped with means for suspension in a crane or the like.
By suspending the boom means freely, sectional members held by the boom means of the gripping means may be oriented in any direction in the horisontal plane. Furthermore, the boom may be brought in position with respect to plates laying in a position with a relatively large slope and it may therefore also handle sectional members which are not straight. In many cases this will give better utilization of the production areas because the panel plates may be oriented in the most suitable direction without regard to particular patterns of the profiles. Also the device according to the invention is substantially simpler and lighter than the previously known devices, thus resulting in great savings. Furthermore, the applicability of the device is increased since it may be used with already existing crane equipment.
Further advantageous features of the invention will be apparent from the following description of the examplifying embodiment shown in the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a device according to the invention in side elevation;
FIG. 2 shows the device of FIG. 1 in plan view; and
FIG. 3 shows the device of FIG. 1 in end elevation.
DETAILED DESCRIPTION OF INVENTION
In FIG. 1 reference numeral 1 generally designates a gantry crane device which is movable on rails 2. The crane device 1 has a crab 3, with a lifting hook 4 on which is suspended a device according to the invention generally designated 5.
The device 5 comprises a boom means 6 which is equipped with gripping means 7 for holding a sectional member 8 during the latter's transportation and positioning on a panel plate 9 resting on supporting rails 10. The boom means 6 is further equipped with lifting magnets 11 for the panel plate 9 and jack means 12 for pressing the sectional member 8 against the panel plate 9 during tack welding of the member and plate together. The boom means 6 also supports a hydraulic unit 13 and a control board 14 for the gripping means 7, the lifting magnets 11 and the jack 12.
The boom means 6 is equipped with a central suspension device 15 including a suspension eye 16 which preferably is rotatable with respect to the boom means. Hereby the boom means may be rotated about a vertical axis as indicated with broken lines and arrows in FIG. 2. The suspension eye 16 may advantageously be connected to a spring device 17 which preferably is adjustable. By the aid of this spring device the sectional member 8 may without difficulty be placed on the panel plate 9 without any substantial part of the weight of the device 5 being transferred to the panel plate and causing undesirable deflection of the plate. This is of particular importance for thin panel plates.
Gripping means includes pairs of legs 7 (FIG. 3) which are pivotably supported at their upper ends in the boom means 6 and are thus mounted thereto, by a suitable means. The legs 7 are pivotable towards and away from each other in a plane extending generally transversally of the longitudinal axis of the boom means 6. This pivotability is indicated in broken lines for one of the legs 7 in FIG. 3. The pivoting motion can advantageously be caused by a hydraulic cylinder 24 (FIG. 3) extending generally horizontally between the legs of each pair and being pivotably connected to both legs. The legs 7 of each pair may thus be clamped against each other for holding a sectional member 8 which concurrently is aligned with a longitudinal axis of the boom. This clamping function may also be utilized for fetching sectional members from a store and bringing them to the correct position on the plate 9 where they are to be welded.
Some of the legs 7 may at their lower end be equipped with rollers 18 (FIG. 2) in order to make the device 5 easily movable on the panel plate 9. The rollers may advantageously be formed by ball rollers so that the device 5 may be moved easily in all directions on the panel plate.
When the sectional member 8 has been positioned as mentioned above, it is lowered onto the panel plate. This is accomplished by letting the rollers 18 move upwards with respect to the legs 7, e.g. by letting the rollers 18 be hydraulically movable in the vertical direction. In this position the sectional member 8 is pressed into contact with the panel plate 9 by releasing the lifting magnets 11 of the boom means holding the boom to the panel plate while the jacks 12 press the sectional member against the panel plate. Thereafter the sectional member and panel plate are tack welded together. If the sectional member is substantially longer than the boom means 6, the first welding will be performed at the middle portion of the sectional member, whereupon one successively works towards the ends. Thus, it is possible to cover a relatively large spectrum of sectional member dimensions with respect to both cross section and length.
The lifting magnets 11 are connected to hydraulic cylinders 19 for the boom means 6 by chains 20. The chains fulfill their function in a particularly advantageous manner by transmitting tension without any possible stretching and concurrently they permit any necessary movability of the lifting magnets in the horisontal plane. The lifting magnets may advantageously also be equipped with a separate quick release pull up means (50) for rapidly moving the magnets away from panel plate 9 and thereby moving them out of the way when sectional members are to be fetched and brought in position. In this case the chains 20 will not be any hindrance due to their lack of rigidity.
The jacks 12, which are used to press the sectional member 8 against the panel plate 9, are mounted to the boom means 6 by a suitable means and may advantageously be equipped with extendable piston rods 21 which may be operated by means of wheels 22. Thus, the jack means may quickly be brought out of the way during transportation of sectional members.
To make the boom device 6 even more applicable, it may be equipped with lifting hooks 23 which preferably are located at its ends. The lifting hooks permit the use of slings, clamps or the like in order to fetch hard to reach sectional members in storage. It may also be advantageous to equip the boom means 6 with its own lamps (not shown) to ensure good working light anywhere the device 5 is to be used. Of course the device will have to be fed with electrical power for the hydraulic unit, the lifting magnets, the lamps, the welding apparatus and any electrical control means. To avoid loose lines and cables on the floor, it may be advantageous to run the power along the suspending crane.
From the examplifying embodiment shown in the foregoing it will be understood that one according to the invention has obtained all its objects in a simple and inexpensive way. In addition, risky use of chains and slings for manuvering the sectional members in place is avoided as is the risk that sectional members may tumble before they are properly tack welded. Furthermore, aligning and positioning of the sectional member can be accomplished very quickly and simply.
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Apparatus for transporting and positioning sectional reinforcement members relative to a panel plate in which a boom is pivotally mounted about a vertical axis and carries a plurality of members for gripping a selective reinforcement member, a plurality of magnets for holding a panel plate and a plurality of jacks for holding a sectional reinforcement member against the panel plate while the member is tack welded to the plate.
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This is a continuation-in-part of pending U.S. patent application Ser. No. 07/612,384, filed Nov. 14, 1980, now U.S. Pat. No. 5,144,326, issued Sep. 1, 1992, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Most military vehicles that are employed with tactical units and transmit and receive communications by high frequency (HF) radio typically utilize tapered flexible vertical antennas called "whips". The most common whips consist of four 4 foot sections (16 foot whip) for use while the vehicle is moving, or eight 4 foot sections (32 foot whip) for use when the vehicle is stationary, referred to as "at-halt" operation. The sections are typically disconnected and stored in a canvas bag or the like during non-use, and are joined with threaded fittings during use. The bottom section has a threaded fitting for attachment to an antenna mount which is attached to a vehicle or shelter.
The vertical orientation of a whip is practical for vehicle mounting and useful for short distance ground wave (also known as surface wave) communications. However, certain intermediate distance communications requires that NVIS (near vertical incidence skywave) propagation modes be employed.
NVIS propagation involves refraction of radiated radio signals off the ionosphere at angles near 90° above the horizontal. High frequency radio signals emitted at high vertical radiation angles are reflected/refracted from the ionosphere at acute angles and return to earth at short and medium distances with usable signal intensity. As a practical matter, NVIS propagation can only be accomplished within the high frequency radio portion of the radio spectrum (about 2-30 MHz). The best results are achieved within the lower frequency portion of the HF band (2-14 MHz). NVIS propagation using the ionosphere cannot be employed with frequency signals greater than about 20 MHz.
NVIS is particularly effective where the participating net stations are spread over geographical areas within approximately 300 miles of each other. For example, if HF radio stations operating on lower HF frequencies (2 to 14 MHz) radiate signals at between 90 degrees (directly overhead) to approximately 45 degrees, the signals will return to earth with considerable strength out to approximately 300 miles (480 kilometers) of the transmitting station.
To produce adequate signal levels at these high angles, sending and receiving antennas optimally should be horizontally polarized. However, the whip antenna, in its normal position, is vertically polarized, i.e., the electrostatic field is perpendicular to the Earth and the electromagnetic field is parallel to the Earth, thus producing low signal levels at high angles. The vertical radiation pattern of a vertical whip operating in the HF radio band has the highest gain at angles below 45 degrees above the horizon. The antenna thus performs fairly well when used for ground wave communication (short distances, usually under 25 miles), but poorly at high radiation angles necessary for NVIS communication.
One method of providing some horizontal polarization for NVIS operation is to bend the whip from the vertical toward the horizontal position to the maximum extent possible. However, because the bottom whip sections are rigid and spring mounts (when used) are stiff, it is difficult to bend the lower sections of the whip to a near-horizontal position where maximum current and radiation occurs. Also, lower whip sections and springs often break when bent too far.
Adjustable antennas for vehicles are known in the art. U.S. Pat. Nos. 4,109,251, 4,243,989, 4,827,273, 4,101,897, 4,055,845 and 4,074,271 each disclose an adjustable antenna mounted on a vehicle. However, the antennas used in the mountings disclosed in these patents are not for high frequency whip antennas. Further, these types of tiltable antennas are quite small and are intended for use at very high (VHF) and ultra high (UHF) frequencies which would normally support antennas no more than about 36 inches long. It would be impractical to use the types of antennas disclosed in the above-mentioned patents in place of the standard HF whip antenna. Also, systems for transmitting VHF and UHF frequency radio waves do not rely on and are not designed for reflection/refraction of such waves off the ionosphere. Therefore, these patents do not suggest tilting antennas for the purpose of utilizing NVIS propagation.
U.S Pat. Nos. 2,934,764, 2,979,729 and 4,625,213 each disclose mounts for antennas. The mounts hold an antenna to a surface in a fixed orientation, and do not provide for easy transition between vertical and horizontal polarization. Further, the disclosed mounts cannot in any way be substituted for a mount on an existing high frequency radio whip antenna connection. Also, none of the patented devices are practical for the exploitation of NVIS propagation phenomena peculiar only to HF radio communication, which is the intended use of the present invention.
There is therefore a need to provide a method and simple and inexpensive device for changing the polarization of an HF radio whip antenna between vertical and horizontal without requiring replacement of the vehicle's existing whip mount or other radio components.
SUMMARY OF THE INVENTION
This need is met by an adapter to which a whip antenna can be fitted in a near-horizontal position (thereby producing horizontal polarization) and in a vertical position, and preferably also in a variety of in-between positions. The electrically conductive L-shaped adapter has a vertical shaft, a near-horizontal member which may swivel or be manually removed and inserted into another position, means for securing the vertical shaft to the mounting base (or a bottom section of the whip antenna) and a port on the upper or distal portion of the near-horizontal member allowing for insertion of the whip antenna section. The means for securing the vertical shaft to the base of the antenna, which is in turn secured to the antenna mount, are located at the lower end of the vertical shaft. The near-horizontal member is connected to the upper end of the vertical shaft. The whip antenna port is located at the end of the near-horizontal member distal from the vertical shaft. In other embodiments, a second whip port is located either at the end of the near-horizontal member proximal to the vertical member or at the upper end of the vertical shaft. The second port may be formed in either the near-horizontal member or vertical shaft or the port may be formed in a vertical post extending from the junction of the vertical shaft and near-horizontal member.
With the adapter, the antenna's polarization can be changed quickly and the vehicle's existing radio antenna coupler and whip can be used for either ground wave or NVIS operation with frequencies of about 2-30 MHz, preferably 2-14 MHz.
The present invention is designed for use with HF radio whip antennas on NVIS operation preferably over the lower portion of the HF band (preferably about 2-14 MHz) by utilizing the reflective/refractive physics of the ionosphere. Accordingly, the present invention provides an adapter (not an antenna and not an antenna base) which can be used with existing whips, whip bases and radio equipment already in a vehicle, and which can be used to tilt an HF radio whip antenna to a position lower than 45° from horizontal, and preferably near-horizontal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a single port adapter having a pivotable near-horizontal member and a securing pin.
FIG. 2 is a schematic side elevational view of a single port adapter having a pivotable near-horizontal member and an internally threaded knurled compression ring.
FIG. 3 is a schematic side elevational view of a single port adapter having a removable and insertable near-horizontal member.
FIG. 4 is a schematic side elevational view of a single port adapter having a pivotable near-horizontal member and a position mechanism which has multiple position selections for the near-horizontal member.
FIG. 5 is a perspective view of a single swivel port adapter having a pivotable near-horizontal member, a slot which allows for an infinite number of positions, and a clamping knob.
FIG. 6 is a schematic side elevational view of a single port adapter having a pivotable near-horizontal member which is positionable at an infinite number of positions by mating plates.
FIG. 7 is a front elevational view of the adapter of FIG. 6.
FIG. 8 illustrates the use of an adapter of the present invention with a rear-tilt antenna.
FIG. 9 illustrates the use of an adapter of the present invention with a forward-tilt antenna.
FIG. 10 is a schematic side elevational view of a two port adapter having as securing means a knurled compression ring that is internally threaded.
FIG. 11 is a schematic side elevational view of a two port adapter having a clamp and pin as securing means.
FIG. 12 illustrates the use of an adapter of the present invention with an antenna in an "at halt" position.
FIG. 13 is a schematic side elevational view of a three port adapter in accordance with the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A whip tilt adapter 10 constructed in accordance with a first embodiment of the invention is illustrated in FIG. 1. The adapter 10 has a vertical shaft 12 and a near-horizontal member 14. The near-horizontal member 14 is attached to the upper end 16 of the vertical shaft 12 and distally terminates in a horizontal port 18. The near-horizontal member 14 is pivotably attached to the vertical shaft 12 by a pivot means 20. That is, the near-horizontal member 14 is attached to the vertical shaft 12 such that the near-horizontal member 14 moves, by pivoting, from a near-horizontal position (illustrated in FIG. 1) to a vertical position (with the member 14 being generally aligned with the vertical shaft 12). The near-horizontal member 14 contains at least one set of holes 22 which corresponds to at least one set of holes 24 on the vertical shaft 12. The near-horizontal member 14 is held stationary with respect to the vertical shaft 12 by a securing means.
In the embodiment illustrated in FIG. 1, the securing means is formed of a pin 26 which is inserted through the matching sets of holes 22, 24, i.e., through the near-horizontal member 14 and the vertical shaft 12. For NVIS operation, the near-horizontal member 14 is in the position illustrated in FIG. 1 and the pin 26 is inserted through the holes 22, 24 located closest to the pivot means 20. For surface wave communications, the pin 26 is removed from the holes 22, 24 (in a direction perpendicular to the plane of the drawing), then the member 14 is rotated about the pivot means 20 until the member 14 is generally vertical (i.e., parallel to the vertical post 12), and then the pin 26 is inserted into holes 22', 24' located relatively farther away from the pivot means 20. Preferably, the pin 26 is held within the holes 22, 24, 22', 24' by a compression spring detent 27.
The vertical shaft 12 may include a bore 28 at its lower end 30. The bore 28 has internal threads which match external threads at the top of the whip mount (or at the top of a first whip section) and thus vary with the specific thread configuration of antenna with which the adapter 10 is used.
The horizontal port 18 is formed with external threads 32 that are compatible with the threads of the bottom of the section of the whip being used. In operation, the whip tilt adapter 10 is attached to a whip, either between the bottom sections or between the whip and the antenna mount or between the whip sections. For practicing the present invention, the whip antenna is preferably from 8 feet to about 32 feet long. The mount may be stationary or mobile, e.g., on a shelter or a vehicle.
In an alternative embodiment, as shown in FIG. 2, the vertical shaft 12 may be secured to the top of a whip section or on the whip mount by a knurled compression ring 34 which prevents the adapter 10 from moving. The compression ring 34 is internally threaded. The internal threads mate with threads 36 on the end of the vertical shaft 12. Additionally, the threaded portion 36 of the vertical shaft 12 is slotted 38, i.e., cut to allow for greater and more secure compression of the shaft 12 onto the base or antenna section.
In other, alternative embodiments, the vertical shaft 12 may be secured through a locking mechanism, preferably a collar, which compresses the vertical shaft 12 onto the lower whip section or base. An example of such a collar is illustrated in FIG. 6. Another alternative to the compression ring 34 is the use of a clamp connected to a pin. The pin fits through the slots of the shaft and causes compression of the shaft around the lower whip section or base when the clamp is tightened. An example of such a securing means is illustrated in FIG. 11.
Alternatively, the near-horizontal member 14 may not swivel but instead may be removed and inserted in other positions. As shown in FIG. 3, the near-horizontal member 14 and vertical shaft 12 each contain one set of matched holes 40. The vertical shaft 12 is configured such that the near-horizontal member 14 fits into designated positions, e.g., near-horizontal and vertical. In order to change the position of the near-horizontal member 14, it is manually removed and inserted into another position. For example, the member 14 can be moved from the near-horizontal position illustrated in FIG. 3 to a vertical position by separating the member 14 from the shaft 12 and then inserting the end 42 of the member 14 into a cavity 44 within the upper end 16 of the shaft 12. The near-horizontal member 14 is secured in position by a securing means, generally a pin which fits into the holes 40.
Alternatively, the near-horizontal member 14 may be attached to the vertical shaft 12 by a multi-position mechanism 46, as depicted in FIGS. 4-7. As shown in FIG. 4, the multi-position mechanism 46 is located at the upper end 16 of the vertical shaft 12. The mechanism 46 may be integrally formed with the vertical shaft 12 and near-horizontal member 14 and may contain matched sets of holes 48. By swiveling the near-horizontal member 14 about a pivot means 20, a hole through the member 14 can be selectively aligned with selected ones of the holes 48 of the vertical shaft 12. The orientation of the near-horizontal member 14 may range from 0 to 180° (90°-180° not depicted in FIG. 4) depending on the position of the holes 48. The near-horizontal member 14 is secured in its selected position by a securing means. Preferably, the securing means is a pin 26 inserted through a selected one of the holes 48 and through the hole through the near-horizontal member 14.
As shown in FIG. 5, the multi-position mechanism may be in the form of an arcuate slot mechanism 50 with a curved slot 52. The slot mechanism 50 allows the near-horizontal member 14 to attain an infinite number of positions and angles with respect to the vertical shaft 12. These angles are not limited to those depicted. The angles can range from horizontal, i.e., 90° to the vertical shaft 12 to vertical, i.e., 180° to the vertical post 12. In the embodiment illustrated in FIG. 5, the slot 52 replaces the holes 48 of the embodiment illustrated in FIG. 4. A clamping knob 54 with a pin 56 is inserted through the slot 52 and through a set of holes through the near-horizontal member 14. When the knob 54 is pressed tightly against the slot mechanism 50, the mechanism 50 is in turn pressed against the near-horizontal member 14, and the near-horizontal member 14 is secured in place.
As shown in FIGS. 6 and 7, the multi-position mechanism may alternatively be formed of two mating cylindrical plates 58, 59 internally faced with interfitting gear-like castellated teeth 60. Only one of the mating plates 58 can be seen in FIG. 6. This plate 58 is preferably integrally formed with (e.g., welded to) the post 12. The other plate 59 (FIG. 7) is essentially a mirror image of the first plate 58. The mating plate 59 is located behind the plate 58 such that the teeth 60 of the two plates 58, 59 mesh with each other. Preferably, the second plate 59 is integrally formed with (e.g., welded to) the near-horizontal member 14.
With the multi-position mechanism 46 illustrated in FIGS. 6 and 7, the near-horizontal member 14 can swivel about an axle 61 and be secured at positions ranging from 0° to 360° with respect to the post 12. The near-horizontal member 14 can be secured in any position by tightening a knob 62 threaded onto the axle 61 (which extends entirely through both of the mating plates 58, 59). Tightening the knob 62 pulls the plates 58, 59 together until the teeth 60 are engaged and interlocked with each other, such that the plate 59 cannot rotate with respect to the plate 58. When the knob 62 is loosened (as illustrated in FIG. 7) the plate 59 can be moved laterally away from the plate 58 and the member 14 can be rotated about the threaded axle 61. When the knob 62 is loosened, the near-horizontal member 14 can be moved to and then secured at a plurality of different angular orientations with respect to the post 12, including vertical. The adapter 10 depicted in FIGS. 6 and 7 also illustrates the use of a collar 64 with a tightening handle 66 for securing the vertical shaft 12 to a mounting base.
The lengths of the vertical shaft 12 and near-horizontal member 14 may vary. The lengths are generally determined by the type of vehicle with which the whip is to be used, or by other practical reasons. The lengths of the adapter's shaft and near-horizontal member must allow the whip to clear the vehicle if the whip is tilted forward, and not drag on the ground if the whip is tilted towards the rear. FIG. 8 shows the use of the adapter 10 for a rear tilt whip 68. The adapter 10 is mounted on an antenna mount 70 on the rear of he vehicle 72 with the whip 68 tilted away from the vehicle 72. FIG. 9 shows use of an adapter 10' for a forward tilt whip 74. In FIG. 9, the adapter 10' is mounted on an antenna mount 76 at the rear of the vehicle 78 with the whip 74 tilted towards the front of the vehicle 78. In the arrangement illustrated in FIG. 9, the antenna whip 74 is partially supported by a front support 80.
The angle formed between the near-horizontal member and the vertical member preferably can be optimized for the user/vehicle antenna onto which the adapter will connect. Generally, the angles employed are between 0 and 45 degrees above the horizontal. If the angle is greater than 45 degrees above the horizontal, the antenna loses its ability to become horizontally polarized and NVIS reception becomes more difficult. Usually, angles between 20-25 degrees above the horizontal are preferred as they allow for optimal radiation/reception at NVIS angles and afford the best practical mountings of the antenna with respect to the shelter or vehicle.
A preferred method of using the adapters 10 illustrated in FIGS. 4-7 is as follows: First, the adapter 10 is installed on a mounting base which is fixed to a vehicle or the like such that the post 12 is vertical. Then, the elongated member or arm 14 is positioned at a 90° angle with respect to the post 12, such that the arm 14 is horizontal. Then, while the arm 14 is horizontal, the long antenna whip is connected to the horizontal port 18. Then, while the whip is threaded onto the port 18, the arm 14 is rotated upwardly to an angle of about 22.5° above the horizontal, and secured in this near-horizontal position by the multi-position mechanism 46, 48, 50, 58-60. With this procedure, the whip can be easily installed onto the port 18, and the flexible whip can then be relatively easily rotated up by hand to a position which is optimum considering the desired polarization of the NVI radio waves and the need to keep the distal end of the whip off of the ground.
The adapter is preferably formed of a conductive material such as aluminum, stainless steel or brass stock and can be formed of machined tubes or cylinders welded together or from a single machined piece. Adapters from machined pieces are preferred simply because their manufacture is easier. By being electrically conductive, the adapter provides a radio frequency electrical connection between the whip sections that it joins. There is no discernible powerloss due in the adapter. Alternatively, the body of the adapter can be formed of poorly conductive or non-conductive material such as a high strength plastic. If the body of the adapter is formed of non-conductive material, then it is necessary to add some type of electrical connectivity means for establishing an electrical connection between the port and the antenna base.
Because the adapter is inserted into the antenna system at or relatively near the base, there is an inherent low voltage (shock) potential even with transmitters with power levels up to 400 watts. The adapters may be insulated to prevent personnel from touching the conductive metal portion. The adapter may be insulated by encapsulating it in plastic, fiberglass or other insulating material.
Another embodiment of the invention is illustrated in FIGS. 10-11. In addition to the features in the above-described embodiments, the adapter 10' shown in FIG. 10 has a second port 82 at an upper end of the vertical shaft 12. The second port 82 is located above a means 84 for securing the near-horizontal member 14 to the vertical shaft 12. In the embodiment illustrated in FIG. 10, the near-horizontal member 14 and the vertical shaft 12 are integrally attached (e.g., welded) to each other.
The vertical second port 82 may be formed with external threads 86 identical to the threads 36 of the first port 18, i.e., compatible with the internal threads of the bottom of the section of the whip being used.
In operation, the whip antenna can be unthreaded from the vertical port 82 and immediately threaded onto the near-horizontal port 18 for NVIS operation. For surface wave communications, the antenna can be threaded back onto the vertical port 82.
The two-port adapter 10' depicted in FIG. 10 has a securing means comprised of a knurled compression ring 34 which fits on the slotted and threaded vertical shaft end, identical to the arrangement illustrated in FIG. 2. The two-port adapter 10' depicted in FIG. 11 has a securing means comprising slots 88 and a control knob 90 with a threaded pin 92. Turning the knob 90 causes the pin 92 to move through threaded holes 94 causing compression of the slotted shaft 12 around the mounting base (or the lower antenna section).
A three port adapter 10" is illustrated in FIG. 13. The adapter 10" is formed of a vertical shaft 12 with a securing means 96 for securing the adapter 10" to a support base (not illustrated in FIG. 13), an integral near-horizontal member 14 with a threaded horizontal port 18, an integral upper portion 16 with a threaded vertical port 82, and an integral intermediate arm 98 with its own threaded port 100. Depending on the configuration of the support base and the angle of the ground underneath the support base, one of the ports 18, 100 or 82 will support a whip antenna (not illustrated in FIG. 13) in an optimum position for radio wave propagation. For example, depending on the conditions, it may be the port 100 which will support the antenna in the most nearly horizontal position. Threads of the ports 18, 82 and 100 are preferably identical to each other. Thus, in operation, the whip antenna (not illustrated in FIG. 13) can be attached to any one of the ports 18, 100 and 82, so as to optimize performance according to the conditions encountered in the field.
In any of the embodiments described above, there is no specific requirement for the ports to be either male or female other than to mate with a particular type/model of whip. Additionally, there is no requirement that the bottom of the vertical shaft 12 has either male or female threads. Both are dependent on the type of user/vehicle antenna to which the adapter will connect. For example, the threads may be Edison or SAE threads which are compatible with AT-1011 32/16 foot fiberglass antennas used by the United States Marine Corps and Air Force and the AN/PRC-104 HF manpack radios, respectively.
The whip tilt adapter of the present invention has the ability to convert a whip from a vertically polarized antenna to a horizontally polarized antenna. To use the adapter, the adapter is first connected to the mating antenna base or bottom whip section. The near-horizontal member is then pointed in the direction that the whip should lie and the whip is then connected to the horizontal port. When using the adapter for a forward-tilt antenna (FIG. 9), it may be desirable to tie the end of the whip to the front bumper, the fording kit, the windshield or other fixed points using nylon or other weather resistant, non-conductive rope or brackets 80. When using the adapter for a rear-tilt antenna (FIG. 8), it may be desirable to tie 102 the whip to the two rear sides of the vehicle to prevent it from flaying when the vehicle is moving. If the 32 foot whip is being used "at halt," the whip can be held in place (off the ground) by a cradle 104 (FIG. 12), which also helps to relieve the strain of the long antenna due to gravitational forces.
As used herein, the term "near-horizontal" means that most of the whip is in a near-horizontal plane. The natural arc of the whip, considering its length and weight, plays a large part with regard to the angle employed in the tilt adapter. For example, a 32 foot whip, with loading coil inserted, could require a 30° or higher tilt angle to allow the whip to lie in a near-horizontal plane and preclude the whip from dragging on the ground. The precise angle employed is designed to accommodate the practical and electrical characteristics of the whip and whip base being employed. Additionally, in some instances, the relationship of the placement of the whip base on a vehicle (shape, height and other characteristics of the vehicle chassis) and configuration of the ground plane require tilting the whip at somewhat higher or lower angles to obtain near-horizontal positioning. By adjusting the angle of tilt, NVIS performance can be optimized for any given vehicular application or ground conditions. The embodiments illustrated in FIGS. 4-7 are particularly well suited for adjusting the angle of the near-horizontal member 14 for optimization of NVIS performance.
Using a conventional, vertical whip antenna with the whip tilt adapter of the present invention eliminates the need to use expensive, bulky, large and mechanically difficult and time consuming solutions using antennas that are made of large diameter copper or aluminum tubing. Additionally, with respect to use on vehicles, the whip-tilt adapter allows the vehicle to function using near-vertical incidence with a physically flexible, electrically efficient, simple and inexpensive antenna.
The drawings and the foregoing description are only illustrative of preferred embodiments which achieve the objects, features and advantages of the present invention. It is not intended that the present invention should be limited thereto. Modifications of the preferred embodiments which come within the spirit and scope of the following claims are to be considered part of the present invention.
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A whip-tilt adapter allows a whip antenna designed for use over the 2-30 MHz frequency band known as the high frequency (HF) radio band that is normally vertically polarized to be horizontally polarized for use in near vertical incidence skywave (NVIS) communication. The adapter has a vertical shaft for connection to an antenna mount or a bottom section of the antenna, a near-horizontal member having a port to connect to the antenna, and optionally a vertical port for an antenna connection. The adapter can be made to mate with any whip and whip base.
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FIELD OF THE INVENTION
The present invention relates to reproduction of images through the use of halftoning and, more particularly, relates to a process of dithering utilised in the reproduction of images.
BACKGROUND ART
Halftoning techniques, such as dithering, are utilised when an output device is unable to display continuous tone values, and on it being to display a limited number of discrete levels for each pixel, The dithering process is intended to produce, on a desired output device having, for example, only a restricted grey scale capability, an image approximating, as close as possible, the original image. Although dithering has been shown to easily extend to multi-level output devices, in addition to colour printing devices, for the sake of clarity, it can be assumed that the output device is of the form of a bi-level black and white printing device.
The process of dithering traditionally involves the creation of a "dither matrix". Image pixel values are then normally compared with a corresponding value in the dither matrix. If the dither matrix value is less than the input pixel value, a marking device, such as a printer or display tube, produces a "on" pixel indication at that particular point.
The number of entries in the dither matrix is normally substantially smaller than the number of entries in the input pixel image. Therefore, the most common technique utilised in the art for addressing a dither matrix is one that utilises modulo arithmetic. This corresponds to repeating or "tiling" the dither matrix over the input image.
The formation of a dither matrix is the most significant portion of the dithering process and the dither matrix should have a number of desirable attributes. These include:
1. The dither matrix should be as large as possible so as to avoid the occurrence of repeated patterns in the output image produced by the repetitive or tiling nature of the dither matrix.
2. The dither matrix should have as fine a "granularity" as possible, the granularity preferably not exceeding the granularity of the input image. Hence, the number of levels that each value within the dither matrix can take should, preferably, be equal to the number of levels that the input pixels may take. This avoids the unnecessary loss of detail in the output image through over quantisation of the input image.
3. With larger dither matrix sizes, it is desirable that the values within the dither matrix be evenly distributed across all possible values of input pixels. This can effectively be achieved by repeating each level, in the dither matrix, the same number of times.
4. The distribution of the dither matrix values should be chosen so as to avoid unwanted artifacts in any output image. Unwanted artifacts can occur in areas of an image that are of the same intensity or slightly varying intensities due to regularities occurring in the dither matrix.
5. At each intensity level, it is desirable that the relevant output marking device creates a half tone image that is as evenly distributed as possible. This requirement can be met by "spreading out" those pixels which will be illuminated at each possible level.
The need to provide a dithering technique that "spreads out" the marked output points at each level is particularly important, as is the need to ensure areas with slightly varying levels of intensity also produce a dithered output where the output pixels are as evenly distributed, or are spread, out as far as possible.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an alternative form of dithering which leads to improved output images for at least some class of images.
In accordance with a first aspect of the present invention there is provided a method of creating a three dimensional halftone dither matrix, the matrix being divided into a predetermined number of levels with each level comprising a two dimensional matrix of activation indicators having positional values including x and y positional components, the method being performed using a computer and including the steps of:
(a) creating a series of three dimensional curves, from a two dimensional array of dither values, the two dimensional array being of the same dimensions as the two dimensional matrix and comprising level value entries, each of the level value entries having a corresponding three dimensional curve, the three dimensional curve starting at a starting level corresponding to the dither matrix value and at a position corresponding to the x and y positional components of the level value entry, said three dimensional curve terminating on the highest level of the three dimensional halftone dither matrix and taking one x and y positional value on each level between the starting level and said highest level,
b) forming an objective function having at least two components, a first component being a measure of the evenness of the distribution of the positional values of the curves for a particular level, and the second component being a measure of the deviation of the curve from a straight vertical line,
(c) optimising the objective function so that the positional values at any of the levels of the series of curves have a high degree of evenness of distribution and the curves have a low degree of deviation from a straight vertical line, and
(d) forming the three dimensional halftone dither matrix wherein said activation indicators are active in positions corresponding to the paths of each of the curves.
In accordance with a second aspect of the present invention there is provided an apparatus for halftoning an input image including:
an inputting device of inputting pixel data values including intensity level and address data, a table look up device, connected to the inputting device, and containing a series of two dimensional arrays constructed in accordance with the preceding paragraph, the intensity level data being used to select one of the series of two dimensional arrays and address data being used to address a data value within the selected two dimensional array, and a marking device, connected to the lookup device, for making an output image when the data value exceeds a predetermined threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the present invention are described with reference to accompanying drawings in which:
FIG. 1 illustrates the process of formation of dither matrices;
FIG. 2 is a graph illustrating the illumination of output pixels when dithered with the first row of the dither matrix of FIG. 1;
FIG. 3 illustrates the illumination of pixels when dithered with the matrices created in accordance with the preferred embodiment;
FIG. 4 is a flow chart of the simulated annealing process utilised in the preferred embodiment;
FIG. 5 illustrates the weighting function utilised in the simulated annealing process of the preferred embodiment;
FIG. 6 illustrates the incorporation of resultant matrices created in accordance with the preferred embodiment into a dithering system for outputting images on a bilevel device;
Appendix 1 is a computer program listing for the creation of a 3-dimensional matrix in accordance with the preferred embodiment;
Appendix 2 is a listing of the simulated annealing library routines; and
Appendix 3 is a listing of the simulated annealing codes.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is shown an example of a 16×16 dither matrix 1. The dither matrix 1 comprises a large number of entries 2, the values of which are initially assigned in accordance with any of the standard techniques, for example the Bayer technique as outlined in standard text books such as "Computer Graphics--Principles and Practice", Foley et al., second edition 1990, Addison-Wesley Publishing Company, Inc. Reading, Mass. at pages 568-573.
However, the preferable method of assignment is as set out in detail hereinafter under the sub-heading "Initial Assignment of Dither Matrix Values". If the entries 2 have been assigned in accordance with the preferred method, the resultant values will produce, at each possible output level, a substantially evenly distributed output. The dither matrix formation process mentioned under the heading entitled "Initial Assignment of Dither Matrix Values" tends to produce a matrix with values distributed in a slightly random pattern due to the nature of the simulated annealing process which is also described hereinafter in greater detail. The first row of dither matrix 1 is shown in FIG. 1 containing a set of sample values which are assumed to form part of the resulting dither matrix after the completion of the assignment process.
Referring now to FIG. 2, there is shown a graph having a first axis (X value) having 16 graduations (0-15) corresponding to the 16 possible column positions of the first row of the dither matrix 1 of FIG. 1, The Y axis is represented by a level scale having graduations from 0-15. If it is assumed that input pixels take on one of 16 separate values (0-15), markers 5, illustrate the level value at which pixels which map to the corresponding X value are turned on. A line 6 illustrates those pixel level values greater than the corresponding marker value 5, which produce a corresponding "turning on" of the output pixel. Hence, if the dither matrix value in column 15 of the first row is 5, all corresponding input pixel level values in the range 5 to 15 cause the output value at this location to be turned on.
The method described hereinafter under the sub-heading "Initial Assignment of Dither Matrix Values" is directed to evenly spreading out those pixels which are currently turned "on" at each level. Of course, FIG. 2 represents only one row of the dither matrix and, as the method is applied in both the X and Y axis of the dither matrix, a three dimensional form of FIG. 2 is created, with FIG. 2 showing a slice through the Y axis at the first row of Y.
Unfortunately, when utilising a dither matrix assignment technique such as the one outlined below, once a dither matrix value 5 has been assigned a position in the array, the corresponding line 6 is fixed for all higher levels. Therefore, even though certain levels, (eg. level 1) may be in some form of equilibrium, the need to turn on more and more pixels within the dither matrix at higher levels disturbs this equilibrium and enforces higher levels to not be in the best possible equilibrium or "spread out" state.
One method which is utilised to overcome this problem is to store a separate bit map for each level indicating whether a pixel is on or off at that level. These bit maps are then separately optimised, for example using simulated annealing, to produce patterns which are of a spread out nature at each level. One such method for optimising separate bit maps for each level of output is disclosed in U.S. Pat. No. 4,920,501 entitled "Digital Halftoning with Minimum Visual Modulation Patterns" by Sullivan et al. However, that method is unsuitable as the separate optimisation of each bit map level has been found in practice not to produce optimal results for most images. Most images often comprise large regions of slowly varying pixel intensity levels. Therefore, in such slow varying areas, only a few contiguous levels are involved. In such areas, it has been found that the independent minimisation of the levels of the dither matrix result in interference effects occurring between levels such as to produce a sub-optimal result, with noticeable clumping of pixels a result of this interference.
In the preferred embodiment of the present invention, the line 6 of FIG. 2 is made to alter its path at higher levels if this results in a more evenly distributed or spaced out pattern, with a penalty being paid for the alteration.
Referring now to FIG. 3, there is shown an example of this process. In this example, a dither matrix value 10 is initially turned "on" in column 14 (X value) at level zero. Subsequently, a determination is made to turn on to the matrix value 11 at level 1. This causes the corresponding path or curve 13 to be altered in the vicinity of a matrix point 11 so as to produce a more spread out distribution at each level. Similarly, path 14 is altered in the vicinity of point 15, and the path 16 is also altered in the vicinity of the point 17. Although movement of the curve 13 from one layer to the next can produce unwanted interference effects, the resultant more even distribution of pixels illuminated at each level also produces an improved output image.
Unfortunately, the number of different combinations possible in optimising the process of the preferred embodiment is excessive. FIG. 3 shows only the X axis of one column. Inclusion of the Y axis adds an additional dimension to the problem. The finding of an exact combination or combinatorial solution of how best to assign values as is practically beyond current day computers for large size dither matrix system.
It should be noted that the preferred embodiment is not a traditional dither matrix system, as a bit map is required to be storm for each level indicating those tither matrix positions that are "turned on" at a particular level.
Additionally allowing the paths eg. 13, 14, 16 to change from the strictly vertical can, in some instances, produces unwanted interference effects between differing levels in slowly varying images.
The Simulated Annealing Process
The extreme complexity of the solution of the bit map production process suggests it is most likely of an NP-complete nature, and hence its attempted optimisation utilising a process such as "simulated annealing" would be beneficial. Simulated annealing is an efficient method for finding an approximation to a minimum value of a function of many independent variables. The function, usually called a "cost function" or "objective function" represents a quantitative measure of the "goodness" of some complex system.
The first step in the simulated annealing method is to generate an objective which has a value dependent upon a set of variables x1 to xm. The values of the variables x1 to xm are given a small random change and the objective is re-evaluated and compared to the old value of the objective. The change in the objective is referred to as Δobj.
If the change in the variables results in a lower objective value, then the new set of variables is always accepted. If the change in the variables results in a higher value for the objective, then the new set of variables may or may not be accepted. The decision to accept the new set of variables is determined with a given probability, the preferred probability of acceptance is: ##EQU1## where T is the simulated "temperature" of the system.
Hence for a given (Δobj), a high temperature T results in a high probability of acceptance of the change in the values of x1 to xm, where as at a low temperature T, there only is a small probability of acceptance. The temperature T is initially set to be quite high and is reduced slightly in each iteration of the annealing loop. The overall structure of a computer program, written in pseudo code, implementing the simulating annealing process is as follows: ##EQU2##
A flow chart for use in implementing the above is shown in FIG. 4. From the flow chart and the foregoing description, it is apparent that the procedure is not unlike the cooling of heated atoms to form a crystal. Hence the procedure is commonly known as "simulated annealing".
Initial Assignment of Dither Matrix Values
The preferred embodiment uses an initial assignment of dither matrix values that are determined by a simulated annealing process and which measure the "bunching" or "grouping" together of pixels of the same colour in the dithered image. By the same colour, it is meant that, for a particular intensity level, two separate dither cell values result in their respective pixels both being on, or both being off. It is likely that nearby pixels of the original image have the same or similar intensities; Therefore it is assumed that the original image has exactly the same intensity everywhere. For a given intensity in the original image, minimising a function of the form as shown in Equation 2 leads to a smoothly dithered pattern for that intensity. ##EQU3##
The function f is preferably one which decreases monotonically with distance, and dist() is a measure of the distance between points p1 and p2.
The preferred measure of distance dist() is the Euclidean distance between the points, but, because the dither matrix is generally repeated in the vertical and horizontal directions, dist() is measured modulo the size of the dither matrix.
If
p1=(x1,y1)
p2=(x2,y2)
are two arbitrary cells in the dither matrix at positions (x1,y1) and (x2,y2), then, for an (n×m) dither matrix, the preferred distance measure is: ##EQU4## where the mod function extends to negative numbers in accordance with the following relation, which holds for all x:
x mod m=(x-m)mod m (EQ 4)
For example, -3 mod 5=2 mod 5=2
The function f() is preferably chosen such that: ##EQU5## where γ is a dispersion strength factor which is preferably equal to 1 although other positive values can be used.
Equation 2 gives the objective function for a single original image intensity level. To obtain an objective function which properly takes into account all possible image intensity levels, an objective function must be created which sums the quantity shown in Equation 2 for all possible intensities, as shown in Equation 6: ##EQU6## where w(intensity) is a weighting factor which assigns a relative importance to image quality at each intensity level. It will be assumed for the purposes of explanation of the preferred embodiment that each intensity level is treated equally and hence all the w(intensity) values are equal to 1.
Alternatively, if the intensity range is scaled to be in the range from 0 to 1, W I (intensity) can be of the following form: ##EQU7##
The preferred form of assignment leads to the final preferred objective function which is: ##EQU8##
To use simulated annealing to optimise a dither matrix, a method of specifying how to apply a random change (mutation) to a given dither matrix is required. The preferred random mutation method is to choose two (x,y) coordinates of the dither matrix using an unbiased random number generator. The entries of the dither matrix at these two places are then swapped. Whether this swap is accepted as the new solution, or rejected and therefore undone, is determined by the simulated annealing criteria previously discussed.
Theoretical considerations indicate that the anneal should begin at a temperature of infinity. In the preferred embodiment, this is achieved by randomly scrambling the dither matrix values by performing the above mentioned random swap process on a very large number of dither cells and accepting all swaps without evaluating the objective function.
Efficiency Methods in the Computation of the Initial Dither Matrix
Unfortunately, the time to compute the required medium or large sized initial dither matrix using the method of the preferred embodiment, in its present form, is excessive. Several methods can be adopted to reduce this time and will now be described.
For an (n×m) dither matrix, the number of entries in the dither matrix is;
#entries=n×m (EQ 9)
Equation 6 requires that each evaluation of the objective function has the following time order: ##EQU9##
For simulated annealing to work, every dither matrix entry must be swapped many times. If an `epoch` is defined to be approximately equal to a number of swaps corresponding to the number of cells in the array (ie. an epoch is approximately equal to n×m), then the simulated annealing process may typically take several hundred epochs. Therefore the time for completion is approximately as follows: ##EQU10##
For a 60×60 matrix for a 256 intensity level input image, annealed for 500 epochs, the number of iterations of the inner loop will be: ##EQU11##
Typical workstation computers can presently perform about 109 iterations per hour, so such a computer would take centuries to complete the above task for the defined array size.
Now, given that D(p) is the dither matrix value at point p, then the number of intensity levels for which two dither matrix locations p1 and p2 will have the same colour (as previously defined) is:
#intensifies p1, p2 have same colour=(#intensities-|D(p1)-D(p2)|) (EQ 13)
Therefore Equation 8 is rearranged as follows: ##EQU12##
This removes the summation over all intensities of Equation 6 resulting in a substantial overall speedup.
The number of intensities (#intensities) is a constant and adding a constant to the objective function does not change the solution resulting from the optimisation. Therefore, this term can be removed from the objective function yielding: ##EQU13##
Further speedups are obtained by noting that the simulated annealing process only requires the computation of the change in the objective function due to the swapping of two dither matrix entries and computation of the objective is not actually required. Most of the points in Equation 15 are unaltered when two dither matrix entries are swapped and only pairs involving one of the two chosen points involved in the swap change their values. The contribution to Equation 15 of a dither matrix entry Dc being located at point pc (ob -- dp) is given by: ##EQU14##
Therefore, the change in the objective function given in Equation 15 due to swapping the dither matrix values located at the points p1 and p2 is given by:
Δobjective=ob.sub.-- dp(D2,p1)+ob.sub.-- dp(D1, p2)-ob.sub.-- dp(D1,p1)-ob.sub.-- dp(D2,p2) (EQ 17)
where dither matrix value D1 starts at point p1 and moves to point p2, and dither matrix value D2 starts at point p2 and moves to point p1.
The evaluation of Equation 17 requires the examination of every point of the dither matrix four times, rather than examination of every pair of points of the dither matrix as required by Equation 15. This again results in a substantial speedup and Equation 16 and Equation 17 are preferably used in the creation of small and medium sized dither matrices. The analysis leading to Equation 16 and Equation 17 can also be applied to the more general Equation 6, leading to the more general formulation for Equation 16 given by: ##EQU15##
The time taken to create a dither matrix using Equation 18 is:
Time for Completion=#epochs×#evaluations per epoch×#time per evaluation =O(#epochs×n.sup.2 ×m.sup.2) (EQ 19)
This compares favourably with Equation 11 and is practical for small to medium sized dither matrices (less than say 5,000 entries).
For large dither matrixes, further speedup is required to make the annealing practical. This is achieved by using simple approximations.
The computation involved in Equation 16 involves an inverse distance relationship. This involves a large number of points that contribute very little to the final result because they are a large distance away from pc which is the point of interest. The approximation involves neglecting the contribution of these points, and only using points which are within a small distance of pc. This imposes a circular window about pc with a radius designated to be "window -- radius",
Equation 16 can thus be approximated as follows: ##EQU16##
Use of Equation 20 is found, in practice, to provide inferior resulting dither matrices because of the discontinuity introduced when the dist() equals window -- radius. This discontinuity is remedied by using instead the following formula: ##EQU17## which removes this discontinuity and is used in the preferred embodiment when a larger dither matrix is required:
The function ob -- dp used in Equation 16 is defined for Equation 18 to be: ##EQU18##
The time to compute initial dither matrixes using Equation 21 or Equation 22 is then of the following order:
Time for Completion=O(#epochs×n×m×window.sub.-- radius.sup.2) (EQ 23)
This is found to be practical even for the creation of very large dither matrices. Reasonable values for window -- radius are found to be between 7 and 12.
In the present embodiment, Equation 21 is used to obtain an initial dither matrix of size 16×16 with each element taking one of 64 possible levels.
Formation of Preferred Embodiment
The formation of the preferred embodiment relies heavily upon the use of simulated annealing. As noted previously, in order to utilise the process of simulated annealing it is necessary to form an objective function. The objective function utilised in the preferred embodiment has two components. The first is a measure of the degree with which the pixel patterns on each level are spread out or distributed. The second factor is a penalising factor which penalises the alteration of the trajectory of paths eg. 13, 14, 16 of FIG. 3. Hence, the objective function involves these two competing factors and is represented as follows:
Objective=Spread out factor+Path alteration factor (EQ 24)
The spread out factor is similar to that disclosed above in relation to the formulation of the initial dither matrix and has the form: ##EQU19## where W I (intensity) is a weighting function which is a function having a relationship to the perceived magnitude by the human observer of each intensity level, with the preferable form being as set out in Equation 7.
Further, the function dist(p1,p2) is a distance measure between the points p1, p2 measured in a modulo sense with respect to the size of the dither matrix.
The path alteration factor is a measure of the amounts that a particular path deviates from a straight line. One such equation is as follows: ##EQU20##
In Equation 26, each point P of a path is represented by a three-tuple, having a x value, a y value, and a level value (l). The second weighting function w p (l 1 -l 2 ) represents a weight applied which is a function of the distance between the two levels l 1 and l 2 . Many different weighting functions can be used, however, FIG. 5 shows the weighting function used with the preferred embodiment which restricts the summation to points which are spaced less than six intensity levels apart. This has the effect of substantially reducing the computational requirements necessary to calculate the Path alteration factor of Equation 26.
The use of the present form of the equation for the Spread out factor (EQ 25), results in an excessive time for evaluation. A number of substantial optimisations can be made to this equation, in addition to the application of a "window of influence" which further substantially reduces the computation time for the evaluation of the spread out factor. These optimisations are as previously set out in relation to the formulation of the initial dither matrix and should be utilised for anything but small matrix sizes. In a preferred embodiment, the equation utilised for the spreading out factor is as follows: ##EQU21## where window -- radius constitutes the window of influence and is preferably set to be seven pixels wide.
A three dimensional form of the initial dither matrix comprising a 16×16 array of X and Y values each having 64 possible levels was subjected to simulated annealing of a corresponding objective function of Equation 24 using the enclosed code on a Sun Microsystems Sparc 2 work station.
Although the present invention could start with any initial form of dither matrix, preferably, the initial dither matrix has some of the qualities 1 to 5 mentioned previously. Therefore, the initial matrix utilised is one constructed in accordance with the principles as outlined previously. The annealing process utilising the two competing objectives of Equation 24 was allowed to run for approximately four hours. Of course, larger dither matrix sizes and longer runs are more desirable, however, the time taken for completion of larger dither matrices will also increase substantially.
When the final series of bitmaps was used to dither a series of test images, it was found to produce superior results to other forms of dithering.
Referring now to FIG. 6, there is shown an apparatus for generating a halftone image utilising the series of bitmaps created with the preferred embodiment. A digital monochrome image composed of pixel values is generated by an input device 20 which can be a scanner device or a personal computer programmed to generate graphical output. The digital image is supplied as six bit pixel values representing one of 64 intensity levels. The x and y location of each pixel on a page is identified by two 16 bit words 28,29. Sixty-four, 16×16 bit half tone dot patterns 22, are generated as previously described and stored in bit pattern memory 24. A six bit level indicator 25 is used to select the requisite level and the lower four bits of the x and y address bits are used to select the relevant bit within a particular level. The output from the halftone bit pattern memory 24 is stored in a page memory 26 at the address specified by the x and y pixel addresses. When the bit map page memory 26 is full, the contents are supplied to a binary marking engine 27 such as a laser or ink jet printing device. Alternatively, if the input is synchronised with the marking engine, the output of the bit pattern memory is supplied to the marking engine without the need for page memory 26.
Appendix 1 included in this specification discloses a C-code program for the creation of a three dimensional matrix, with two dimensions being x and y and the third being the level, in accordance with the above embodiment. The enclosed code relies on a number of library routines, including a number of simulated annealing library routines, developed by the present applicant and utilised by the preferred embodiment and outlined in the manual entry set out in Appendix 2. The annealing codes are themselves set out in Appendix 3.
The foregoing describes only one embodiment of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention.
For example, different formulations of the objective encompassing the spirit of the invention would be readily apparent to those skilled in the art in addition to different formulations of the weighting functions used in the preferred embodiment.
Additionally, the present invention can be readily applied to the display of colour images through the application of the preferred embodiment to each colour component of the image. Additionally, the extension of the invention to multi-level output devices will also be apparent to those skilled in the art. ##SPC1##
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A method of creating a three dimensional halftone dither matrix, in which the matrix is divided into a predetermined number of levels with each level comprising a two dimensional matrix of activation indicators having positional values including x and y positional components. The method includes the steps of firstly creating a series of three dimensional curves, from a two dimensional array of dither values, the two dimensional array being of the same dimensions as the two dimensional matrix and including level value entries, each of the level value entries having a corresponding three dimensional curve, the three dimensional curve starting at a starting level corresponding to the dither matrix value and at a position corresponding to the x and y positional components of the level value entry, the three dimensional curve terminating at the highest level of the three dimensional halftone dither matrix and taking one x and y positional value on each level between the starting level and the highest level. Secondly, the method forms an objective function having at least two components, a first component being a measure of the evenness of the distribution of the positional values of the curves for a particular level, and the second component being a measure of the deviation of the curve from a straight vertical line. Thirdly, the method optimizes the objective function so that the positional values at any of the levels of the series of curves have a high degree of evenness of distribution and the curves have a low degree of deviation from a straight vertical line. Lastly, the method forms the three dimensional halftone dither matrix wherein the activation indicators are active in positions corresponding to the paths of each of the curves.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Application No. 60/083,372 filed Apr. 28, 1998.
FIELD OF THE INVENTION
This invention relates to screen displays for the automatic testing of bare printed circuit boards, and more particularly, to a screen display for a fault verification and repair station.
BACKGROUND OF THE INVENTION
Traditional manual bare circuit board fault verification has been a tedious process. Most of the associated equipment merely provided a visual aid in the fault verification process. Typically a flying prober would be utilized for this purpose which traditionally was used to test prototype circuit boards providing the benefit that a test fixture did not have to be devised for the prototype circuit board. Using a flying prober provided the benefit of making it easier to test fine pitch test sites on the circuit boards. A problem with flying probers is that they are slow in testing the circuit board due to the requirement for manually contacting each required test site on the circuit board, which in contrast to a fixture which can test all the test sites on the circuit board simultaneously.
Traditional repair stations have also been used for fault verification for bare circuit boards. Traditional repair stations are graphics based having software which illustrates the circuitry to indicate where the possible failure could be. The repair station utilizes the failure data from the tester and verifies the failure data by hand placement of probes. Software used in connection with traditional repair stations provides risk areas for areas such as shorts or opens based upon the physical layout of the circuitry and the likelihood of conductors in close proximity to each other. Plasma displays including a glass hood where the circuit is projected and the error is highlighted also have been used in repair stations. This method is unacceptable due to the ever shrinking size of today's circuit boards and the associated closeness of test locations. Conventional repair stations simply helped an operator locate a failed net end point designated by the tester, but stopped short of helping verify the fault and tracking down the location of the actual defect.
Flying probers have also been used in the repair process to verify error data from a tester. Typically there are two kinds of flying probers, namely, vertical probers and horizontal probers. In a vertical flying prober, the circuit board to be tested stands vertically upright and a probe contacts the board from either side depending upon the test site locations. The board is manually loaded and held in an upright position by hand manipulated clamps which are moved to the appropriate position and tightened to secure the circuit board. A disadvantage with vertical flying probers is that it is time consuming to manually move each clamp into position and manually manipulate the clamp to secure the circuit board. In the horizontal flying prober, the circuit boards are manually loaded into a drawer which is pulled out from the frame structure of the prober. Clamps hold the board to secure the circuit boards in a horizontal position. Again, the disadvantage in a horizontal flying prober is the time consuming and labor intensive procedure of manually loading boards in the drawer for testing.
Previous repair stations could not provide the user the ability to simultaneously view the board being tested in full along with particular potential failure areas highlighted against a standard to easily and quickly locate, identify and verify the error data. Consequently, a need exists for a flying prober verification and repair station with a screen display with an improved ability to track down the location of an actual defect and verify the fault.
SUMMARY OF THE INVENTION
The present invention is a novel screen display for an automated bare board fault verification and repair station having a locating and loading mechanism which atomically secures the circuit board to be tested or unit under test (UUT) in position. The fault verification and repair station of the present invention will also be referred to as a flying prober. The flying prober of the present invention includes, preferably, two pairs of X-Y-Z prober heads positioned one pair on each side of the unit under test which move independently across the surface of the circuit board to contact the desired test locations on the circuit board. Although two prober heads are preferred, more or less can be used, and on one or both sides of the UUT. The flying prober further includes electronic hardware and software for measuring isolations and continuities of the test sites electrically connected to the prober heads. The prober further includes a loading and locating mechanism for automatically securing the unit under test on the prober relative to the prober heads.
The loading and locating mechanism includes an upper housing and a lower housing one each positionable at opposite ends of the circuit boards. The housings include a lower lip for resting the edges of the circuit board on the housing. The lower housing is fixed on the frame of the flying prober and the upper housing is adjustable by screw clamps to accommodate different sized circuit boards. Positioned inside each of the upper housing and the lower housing is a movable clamping block having a plurality of finger springs rotatable by a dowel rod to lift and lower the springs above the upper surface of the circuit board. An air cylinder on either end of the clamping blocks moves the clamping block forward and backward. Similarly, an air cylinder, or other suitable actuator rotates the dowel rod to raise and lower the finger springs.
A camera is located on the prober head to view both the test probe in the prober head and the test site to verify the test probe is making contact with the test site. The camera image is generated on a computer screen for viewing by the operator of the verification and repair station.
In operation, the upper housing is manually set to the desired positioned according to the specific size of the circuit board to be tested by securing the screw clamps to the frame. The circuit board to be tested is then positioned on the housing such that the edges of the circuit board rest on the lip of the upper and lower housing. Because the frame is angled, gravity allows the circuit board to be located on the clamping mechanism. With the finger springs in a raised position, the clamping blocks are actuated forward towards the circuit board to position the ends of the finger springs over the edge of the circuit board. The dowel rod is then actuated to lower the finger springs into contact with the upper surface of the circuit board along the edge to securely clamp the circuit board in the flying prober. The prober heads are then actuated across the surface of the circuit board to conduct the fault verification process. The dowel rod, clamping block and prober heads are automatically operated and controlled by the software programed within the flying prober. The test probe contacts the test sites and the camera projects the image to verify contact between the test probe and the test sites.
The verification and repair station initially reads a data file corresponding to the circuit board to be tested. The station then reads in the error file from a grid tester or prober which prints a bar card report. Next, the verification process generates files that include all of the defect locations, identifications and video images. When the optional bar code is scanned at the repair station, the repair operator is led defect by defect through the unit under test. The CAD data is cross-referenced with the failure data location. Software includes the ability to evaluate which risk area has a higher probability of having the error location by strategically choosing test locations to measure resistance levels between the locations and choose risk areas based upon lowest resistance measurement between those test locations. This is accomplished by starting with the risk area with the closest test site locations and choosing test site locations closest to the risk area by measuring the resistance between those test sites. A digital multi-meter is connected to the prober head to measure the resistance levels for the test site locations. The prober heads automatically move to the exact location of the first reported fault to make a precise resistance measurement on the pair of failed nodes. When the end points are verified, the reported fault is identified as either false or real. Once the fault has been verified, the repair station uses a real-time high-resolution video camera to magnify the image of high risk locations.
The screen display is divided into quadrants in which a first quadrant depicts a real-time camera view of the unit under test, in a second quadrant a detailed CAD view mated to the camera view in size, position and orientation is depicted, in a third quadrant an orientation view of the entire unit under test is depicted, and in the fourth quadrant user input/output dialogs and buttons are displayed. The real-time camera view of the unit under test can be panned to depict any location of the unit under test. The real-time camera view can be compared to the detailed CAD view of what the circuit board should comprise to easily identify the error. The repair station also includes the ability to mark the location of the error with an electronic marker for subsequent repair. The software marks and describes the error to generate a report for subsequent repair.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the flying prober of the present invention;
FIG. 2 is an exploded assembly view of the locating and loading mechanism of the flying prober of FIG. 1.;
FIG. 3 is a flow chart diagram for the display window of flying prober of FIG. 1; and
FIG. 4 is a schematic illustration of the screen display of the flying prober of FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 illustrates the automated bare board fault verification and repair station, and hereinafter referred to as a flying prober 10 of the present invention. The flying prober includes an angled frame 12 supported upon a base 14 and an input station 16 positioned adjacent the angled frame 12 . The angled frame includes at least one prober head 18 , and preferably two prober heads for movement across the surface of a bare printed circuit board or unit under test 20 . The prober head includes a camera 21 positioned to view the test probe 23 as it makes contact with a test site on the unit under test. The unit under test is positioned within the angled frame by an automated locating and loading mechanism 22 positioned within an opening 24 in the face 26 of the angled frame 12 .
As also seen in FIG. 2, the automated loading and locating mechanism 22 includes an upper housing 28 and a lower housing 30 . The upper and lower housings are positioned within the opening in the angled frame at a distance away from each other corresponding to the width of the unit under test 20 . Lower housing 30 is rigidly positioned in the angled frame by mounting blocks 32 positioned on either end of the housing. The upper housing 28 includes a body portion 29 and a cover 31 which are moveable to accommodate varying width circuit boards to be tested by having mounting blocks 34 positioned on either end of the upper housing which are connected to a screw clamp 36 adjustable within vertical slots 38 in the face 26 of the angled frame. Screw clamps 36 are adjusted by rotation of knobs 40 to loosen and tighten the screw clamp along the desired location of the vertical slot. Both the upper and lower housing have a lip 42 extending along the surface adjacent to the unit under test. The lips 42 can be integrally formed within the upper or lower housing or can be a separate component fastened to the housing by screws, rivets, etc. The lips form a surface for receipt of the unit under test.
Considering the loading and locating mechanism 22 is positioned within the angled frame, the mechanism is also in an angled position thereby allowing gravity to initially hold the unit under test between the upper and lower housing on the lips. The unit under test is simply placed by hand between the upper and lower housing against a stop 44 located on the left hand side of the housing which is the prober location for registration by the prober heads.
The unit under test is held in position between the upper and lower housing by a plurality of finger springs 46 extending from both the upper and lower housing and are positioned along the length of a clamping block 48 positioned within the upper and lower housing. The clamping block 48 is secured within body portion 29 by blocks 49 located on either end of the body portion. The finger springs are positioned along the length of a clamping block wherein each finger spring is positioned within a groove 50 corresponding to the width of each finger spring. Preferably the finger springs 46 are secure to the clamping block by screws 52 . The finger springs extend beyond the edge of the clamping blocks. The fingers springs are raised and lowered by a dowel rod 53 positioned within a groove 54 extending along the length of the clamping block. The dowel rod has a plurality of notches 55 corresponding to the width of the finger springs. The finger springs are lowered to their unit under test engaging position by rotating the dowel rod so that the notches in the dowel rod are adjacent the finger springs. The finger springs are raised by rotating the dowel rod thereby moving the notches in the dowel rod away from the finger springs so that the non-notched portion of the dowel rod lifts the finger springs upperwardly and away from the unit under test. The dowel rod is rotated by a liner actuator 56 , such as an air cylinder.
The clamping block is moved toward and away from the unit under test also by a liner actuator 58 , such as an air cylinder. The liner actuators for the dowel rod and the clamping block are attached to the upper and lower housing.
When the unit under test is loaded into the upper and lower housing the clamping block is in its retracted position and the finger springs are in their raised position. The clamping blocks are then moved forward positioning the bent end of the finger springs over the edge of the unit under test. The dowel rod is then actuated to lower the bent ends of the finger springs on to the upper surface of unit under test thereby securely clamping the unit under test on the lips of the upper and lower housing.
The fault verification is then performed by moving the prober heads over the surface of the unit under test to make contact with the desired test locates on the unit under test.
As seen in FIG. 1, first an operator scans a bar code on an error tag generated from a tester for a particular unit under test. A bar code scanner 60 is located on the input station 16 . The fault file 61 is instantly imported to the computer screen 62 . Next, the unit under test is loaded into the locating and loading mechanism 22 . The unit under test is slipped into the preset position which eliminates the need for board specific tooling hardware. The prober heads automatically move to the exact location of the first reported fault and make a precise resistance measurement on the pair of failed nodes. When the end points are verified, the reported fault is identified as either false or real. Once the fault has been verified the real-time high-resolution video camera 21 magnifies the image of high risk locations. The actual area of the circuit board is viewable on the computer screen for a visual inspection as to whether a defect exists and to verify that the test probe 23 is making proper contact with the test location.
As shown in FIGS. 3 and 4, the flying prober 10 includes a novel screen display 100 . FIG. 3 illustrates a flow diagram depicting the function of the software used in generating the screen display and performing the fault verification process. All views of the unit under test are created with standard Microsoft CView and CDialog Classes. Standard Microsoft Foundation Class (MFC) document/view architecture is used to store data and generate graphical views of the data 101 . A single Document Interface (MFC SDI) is used to attach the graphic views to the document data 102 . The screen display 100 is split into four equal sized views. The first view 103 , is the upper left view port labeled as Camera View, is updated in real time by video card/camera combination that allows the camera image to be directly transferred to a video RAM via supply dynamical link library. The second view 104 is a board orientation view port located in the lower left quadrant of the display screen 100 . The view is based on MFC CView Class with logical coordinate systems set to maintain view of entire board with visual indicators as to current location, side and networks being diagnosed. The third view 105 is a detailed CAD view of the board in the upper right quadrant of the screen. This view is based on MFC CView Class with logical coordinates set to match the camera field of view size and orientation to allow the user to directly compare what artifacts should be on the board (detail view) and the artifacts that are on the board (camera view). The fourth view 106 is user input/output dialogs. These dynamic dialogs are all based on MDF CDialog Class and have in common buttons with universal graphics and text that change based upon the type of defect being verified and/or located on the board.
The camera side 107 is continuously monitored and the camera channel is changed from the front side camera to the back side as needed based upon the side of the unit under test being inspected. The camera side 108 is continuously monitored and the graphic layer displayed is changed as well as the orientation from the component (front) side to the circuit (back) side as needed based on the side being inspected. The defect is verified 109 as being real or false by placing the probe on both of the failed test pads and measuring the resistance.
The resistance is measured by a digital mult-imeter, preferably a Keithley Instruments Model 2400 Source Meter. If the defect is verified as valid, the defect type 110 is established. If the defect is real and not repairable, the board is scrapped. If the defect is real and repairable, then either the open search or the shorts search is implemented based on the defect type. If the defect is false, the board is returned to test.
If the defect is a short, risk zones 111 which are areas of likely defects are calculated based upon the proximity of the networks. Areas that cannot be viewed such as internally to the unit under test are removed 112 . Areas are sorted 113 so that the most likely areas and the areas with a history of previous defects are displayed first with the least likely areas displayed last. Zones are displayed 114 with camera and detail views showing each area and allowing the user to determine when the camera (board) does not match the CAD (design) data in such a manner as to cause the short. When the defect is located, it is marked 115 with an electronic arrow and a picture of the defect from the camera view with the electronic arrow is saved in a graphic file for recall later.
When the defect type is an open, risk zones or areas of likely defects are calculated based on network traces 116 . Areas that cannot be viewed because they are internal to the board are removed 117 . Areas are sorted 118 so that the most likely areas and the areas with a history of previous defects are displayed first, least likely areas last. Zones are displayed 119 with camera and detailed views showing each area and allowing the user to determine when the camera (board) does not match the CAD (design) data in such a manner as to cause the open. When the defect is located, it is marked 120 with an electronic arrow and a picture of the defect from the camera view with the arrow is saved in a graphic file for recall later. Detailed CAD views and camera views are always matched in position, size and orientation 121 so the user can see the differences between the board and the CAD view, thus locating the defects. The networks associated with the defects are always highlighted 122 in unique colors to help the user focus on the nets involved rather than other artifacts not connected with the defects. The display window also includes a standard tool bar menu 123 positioned across the top of the display window 100 .
The camera view is registered with Windows O/S and is updated continually via IMSCan 32.DLL. The board view is displayed with a logical coordinate system set such that the board fills the orientation view window. The detailed CAD view is slaved to the camera view such that the size, orientation and positions match. The user input/outputs are based on Microsoft CDialog Class with contents based on contextual requirements.
The screen display of the present invention can also accommodate multiple levels of detailed zoom camera views. For instance, the screen display can include multiple levels of zoom simultaneously to minimize manual graphic manipulations. In such an instance, the screen display would, for example, include in the lower left hand quadrant a graphical representation of the circuit on the unit under test. In the upper left hand quadrant a mid-level zoom camera view of the circuit board would appear. In the upper right hand quadrant a further detailed zoom of the circuit on the unit under test would appear. In the lower right hand quadrant the user input/output dialogs would be present.
Although the present invention has been illustrated with respect to a preferred embodiment thereof, it is to be understood that it is not to be so limited since changes and modification can be made therein, which are intended to be covered within the scope of the invention as hereinafter claimed. For example, although the screen display has been illustrated with respect to a flying prober, the display could be utilized with other types of circuit board test equipment.
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A flying prober having at least one prober head for contacting test sites on a unit under test which is programed for measuring isolations and continuities of test sites through the prober head. The prober heads include a camera and a test probe wherein the camera views and verifies contact between the test probe and the test sites. A display screen illustrates at least a real time camera view of the unit under test and a computer generated detail view of the unit under test for comparison.
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CROSS REFERENCE TO RELATED APPLICATION
This application is related to Ser. No. 10/268,214, entitled “TAPE MEASURE RECORDING DEVICE”, abandoned. The entire contents are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to erasable whiteboards and, more particularly, to a new erasable whiteboard that can be conveniently mounted onto a tape measure.
DESCRIPTION OF THE PRIOR ART
A white laminate display panel commonly known as a “whiteboard” has all but replaced the classic chalkboard (a.k.a. blackboard) everywhere from classrooms to boardrooms. Like a chalkboard, use of a whiteboard involves writing on the board that can later be erased, allowing reuse of the board indefinitely. This writing is accomplished with a standard carpenter's pencil or, if preferred, by using a pen containing ink specially formulated for quick drying and the ability to be easily erased. Erasure is much easier than a chalkboard, often able to be done with just a finger, thus making whiteboards ideal for rapidly changing notes or figures such as measurements.
Tape measures are compact and portable devices of varying size and shape used for measuring lengths. Often many lengths are measured simultaneously making it desirable to write down these various lengths to avoid confusion. Whiteboards are ideal for such notes but are usually too large and cumbersome for most workshops or construction sites. Thus, it is desirable to have whiteboards of various small sizes that can easily be attached to varying sizes of tape measures.
Numerous innovations for whiteboards have been provided in the prior art that are described as follows. Even though these innovations may be suitable for the specific individual purposes to which they address, they differ from the present invention as hereafter contrasted.
U.S. Pat. No. 6,158,138 discloses a measuring tape pencil sharpener combination is provided including a housing. A measuring tape is coiled within an interior space of the housing with a free end extending from the housing. A lid defines a compartment and is pivotally coupled to the housing and has a closed orientation in abutment with the housing and an open orientation for allowing access within the compartment. A pencil sharpener is provided for sharpening a pencil and depositing shavings within the compartment of the lid.
U.S. Pat. No. 6,393,710 discloses a combination tape measure and straight edge apparatus includes a first straight edge segment which includes an outer edge and an inner edge which includes first hinge members. A tape measure assembly support unit includes second hinge members that engage the first hinge members. A tape measure assembly is provided, and a connector is provided for attaching the tape measure assembly to the tape measure assembly support unit. The second hinge members of the tape measure assembly support unit permit the tape measure assembly support unit and the attached tape measure assembly to be rotated around the first hinge members so that the tape measure assembly can selectively be moved to and from a storage orientation and a plurality of in-use orientations. A second straight edge segment and a third straight edge segment form an isosceles right triangle along with the first straight edge segment. The tape measure assembly support unit includes riser members which support the second hinge members. A support floor supports the riser members which extend downward therefrom. The bottom of the tape measure assembly rests upon the support floor. A first standing wall and a second standing wall are connected to the support floor and extend upward therefrom. The tape measure assembly is connected to the first standing wall. A lock tab support extends upward from the second standing wall, and a pair of lock tabs on the lock tab support engage inside locking portions of the respective second and third straight edge segments.
U.S. Pat. No. 5,079,851 discloses a tape measure having a writing member. The writing member has a front surface for receiving markings and a back surface with an adhesive connected to the back surface for attaching the writing member to the tape measure device.
U.S. Pat. No. 5,845,413 discloses a note pad holder is secured to a tape measure of the type including a box-shaped housing having a planar front wall, a planar back wall which is parallel to and spaced from the front wall, a top wall, a bottom wall, and a pair of end walls. A tape reel is provided within the housing for dispensing tape through a horizontal aperture formed in one of the end walls. The note pad holder includes a flexible sleeve sized to fit snugly over the front, back, top and bottom walls of the housing of the tape measure. The note pad holder further includes a pocket formed on the sleeve in a position in which it is adjacent one of the front and back walls. The pocket is sized for receiving therein a note pad. Other embodiments of the note pad holder are further contemplated.
U.S. Pat. No. 5,459,942 discloses a single thickness metallic notation plate for use in combination with today's plastic cased measuring tapes. During manufacture, the metallic notation plate is pressed into a slightly concave shape. The concave surface is pressed against the tape case surface which ensures that the metal edges snug tightly to the tape perimeter for user-friendly contact. The plate is held in place by factory applied, paper protected adhesives. Notations are erased with a rubber eraser or by moistening the plate and rubbing off with finger pressure. When the plate surface becomes too scratched and unusable, it is stripped off and a new one is applied.
U.S. Pat. No. 4,786,010 discloses an erasable writing tablet for notation of dimensions and other information. The erasable writing table is adapted to be attached to a tape measure or any other conforming receptive surface. The material composition of the erasable writing tablet is sold under the trade name “Corian”. The abrasiveness of this material permits the effacement of the notations by sandpaper or an eraser while maintaining the desired surface properties of the erasable writing tablet. A storage pocket is adapted to receive the means for effacing writing on the erasable writing tablet.
U.S. Pat. No. 5,430,952 discloses a tape measure and accessory combination comprises a housing, with a retractable tape measure housed therein, which can be extended through a slot in the housing, a blade mounted adjacent the slot so that said blade can use the tape as a straight edge for cutting and scoring. A flashlight bulb is mounted so as to shine along the tape measure when extended, and other accessories can be provided, such as a note surface or pad, a pencil or, and an angle finder incorporating a bubble vial.
U.S. Pat. No. 4,965,944 discloses a measuring rule employs a casing which permits marking of lines perpendicular to an edge of the work piece, as well as serving to enable measuring and marking of lines at each of a range of angles thereto.
U.S. Pat. No. 5,575,506 discloses a writing pad for attachment to the clip of a standard tape measure. The writing pad is made from a substantially rigid material, having at least one writing surface, the writing surface being sufficiently hard and abrasive to permit the writing surface to be marked by a standard writing instrument. The writing pad further includes an opening adjacent an edge of the writing pad, creating a lip dimensioned to releasably engage the clip of a standard tape measure. In use, the opening is passed around the clip to releasably secure the writing pad to the tape measure.
U.S. Pat. No. 7,712,226 discloses a grid system apparatus comprising a substantially planar base member and an attachment member. The base member has an upper surface and a lower surface opposite of the upper surface. The attachment member is mounted to the lower surface of the base and is compatible with the lower surface of the base which facilitates releasable attachment of the base member to an outside surface. The base member and the attachment member are configured as a plurality of border members which cooperate to define a plurality of voids there between. The border members include a plurality of outer border members defining an outer periphery thereof, and a plurality of inner border members defining the plurality of voids. The outer border members and the inner border members interface at intersection regions.
U.S. Pat. No. 7,549,235 discloses a multifunctional tape measure device includes a housing, a tape reel which is mounted within an interior chamber of the housing, a flexible measuring tape which is wound on the tape reel and which extends through an aperture formed in the front wall of the housing and a brake for releaseably holding the extended measuring tape. A magnet is rigidly mounted within a recess formed in the bottom wall of the housing and a light is mounted within the housing and is manually operable for generating a visible light beam. A magnifying lens is attached to the housing adjacent one of the first and second side of the housing. A writing surface is retained within a recess formed in an opposed one of the first and second side of the housing and a holder is provided on the housing for retaining a writing instrument.
U.S. Pat. No. 4,766,673 discloses a multifunction combination tape measuring device includes a housing and a tape reel rotatably received in the housing and wound thereon with a flexible tape. The device is characterized by the housing being formed integrally into various functional components such as a sharpener and a draw knife for sharpening pencil, a holder for retaining pen or pencil therein and a shallow groove for retaining memo pads thereon and with a hard-copy writing surface made of suitable material such as P.V.C. and mounted thereon to provide a reusable reserve writing surface. Pencil shavings collecting compartments are provided having exits for disposal of shavings. By such an arrangement of the invention it allows the use of tape measure in a most convenient and effective way for a user at any job site.
U.S. Pat. No. 6,910,280 discloses a tape measure that incorporates a marking device for allowing an individual to measure and mark a wide variety of materials in a more efficient and economical manner, and for measuring and marking the beginning point of reference and the measured position point simultaneously. The tape measure has a housing, a coiled measuring tape, a tape tip, and a marker having a marking wheel mounted on an axle.
U.S. Pat. No. 7,076,885 discloses a tool and tool holder with a permanent magnet mounted upon one and a magnetically permeable keeper on the other are provided with respective camming surfaces which are cooperatively engaged when the tool is rotated, breaking the magnetic attraction between opposing surfaces of the magnet and keeper to facilitate removal of the tool from the holder. A cup-like receptacle is mounted upon a body portion of the tool, disclosed in each of two embodiments as a flexible, metal measuring tape contained within a hollow housing, and one of the magnet and keeper is disposed within this receptacle. The camming surface on the tool comprises convex protrusions within the receptacle in a first embodiment, and protrusions extending outwardly from the periphery of the receptacle in a second embodiment. A recess is formed in a surface of the holder to receive the receptacle on the tool when the latter is releasably mounted upon the holder. The other of the magnet and keeper, as well as the camming surface on the holder, is disposed within the recess. A receiver and indicator may be attached to or integrally formed in the tool, to be activated by a signal from a transmitter, which may be attached to or integrally formed in the holder. When activated, the indicator provides a visible or audible indication to aid in locating the tool when it is separated from the holder. Belt loops and a pencil holder may be integrally formed with the holder body portion.
U.S. Design Pat. No. D602,792 illustrates a notepad holder for tape measure.
U.S. Design Pat. No. D499,136 illustrates an erasable jotting pad with pressure adhesive for attaching to tape measure.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, a removable reusable attachment tool includes at least one magnetic component, an adhesive coating at least one surface of said at least one magnetic component, and a reusable writing component having a first surface securely affixed to said at least one surface of said at least one magnetic component by using said and a writing surface.
According to another aspect of the invention, the at least one magnetic component magnetically attaches to a tape measure.
According to another aspect of the invention, the tool is configurable to be different sizes.
According to another still aspect of the invention, a second magnetic component and a second adhesive coating at least one surface of said second magnetic component.
According to another yet aspect of the invention, a method for providing a whiteboard work surface on various sizes of tape measures for the purpose of recording information on the measuring tape, the method includes fabricating a whiteboard suitable for attachment to a tape measure; attaching at least one magnetic component via an adhesive to a rear portion of the whiteboard; and magnetically attaching said whiteboard to said tape measure.
According to another still yet aspect of the invention, a method for providing a whiteboard work surface on various sizes of tape measures for the purpose of recording information on the measuring tape, the method includes fabricating a whiteboard suitable for attachment to a tape measure; attaching at least one magnetic component via an adhesive to a rear portion of said whiteboard; attaching a second magnetic component via a second adhesive to said tape measure; and removably magnetically coupling said one and second magnetic components.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 depicts an embodiment of the present invention.
FIG. 2 depicts another embodiment of the present invention.
FIG. 3A depicts an application for an embodiment of the present invention.
FIG. 3B depicts another application for an embodiment of the present invention.
FIG. 3C depicts still another application for an embodiment of the present invention.
FIGS. 4 , 5 , and 6 depict front views of the invention having various sizes.
DETAILED DESCRIPTION
The present invention describes a white laminate display work board commonly known as a “whiteboard” that can be easily attached to a multiplicity of differently sized tape measures.
Tape measures are commonly used to measure a multiplicity of lengths both simultaneously and consecutively. These lengths need to be written down to avoid confusion and to be accurately remembered. Because such notes are constantly changing as new measurements are taken, an easily erasable surface such as a whiteboard is ideal. Most whiteboards are too large and cumbersome to be useful, thus it is desirable to have whiteboards of various small sizes that can be easily attached to any size tape measure.
This invention enables users to have a convenient notepad always on hand that is cost-effective and can be attached to any old, new or used tape measure with ease. This concept provides for flexibility, by working around the basic architecture of any tape measure. The present invention involves three sizes of work boards made of finished PVC and can be applied to any tape measure with the provided clear heavy-duty mounting tape. The advantage of the present invention is that it is small, easily portable, and can be reused for notes or calculations indefinitely. It can be used on the work site, in the shop or at home. The user can write down measurements or lists and then quickly erase them with a thumb or finger when they are no longer needed.
Anyone who uses a tape measure should find this invention an ideal alternative to pencils, paper and easily misplaced lists and notes on measurements.
Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.
The present invention is a display panel commonly known as a whiteboard that can be easily attached to a multiplicity of differently sized tape measures. The essential part of the invention is the varied sizes of whiteboard, shaped for a perfect fit on a multiplicity of tape measures combined with the quick and efficient securing device that is the heavy-duty mounting tape.
Referring to FIG. 1 , a writing surface 20 has an entire surface that is coated with an adhesive 21 . A magnetic material 22 is secured to the writing surface 20 via the adhesive 21 . The writing surface (A) can be rounded edge square shape with an arched topside and two rounded corners on the bottom side. The writing surface is perfectly sized for tape measurers. Alternative writing surfaces (B or C) may be used for other size tape measurers. Writing surfaces (B or C) can be circular disks or square shape
The writing surface 20 is removable attachable to a metal housing tape measure 10 via the magnetic material 22 as shown in FIG. 3A . The writing surface 20 allows for reusable applications and notations thereon. For non-metallic tape measures, the invention uses additional components as shown in FIG. 2 .
Turning to FIGS. 2 and 3B , a second magnetic material 23 is coated with a second adhesive coating 24 . The second adhesive 24 attaches to a non-metallic tape measure 10 ′ thereby allowing the writing surface 20 to be removable attachable. The writing surface 20 can be embedded in a tape measure as shown in FIG. 3C .
It may desirable to have the writing surface 20 be removably embedded within tape measure 10 ″. As shown in FIG. 3C , a magnetic material 23 ′ is securely mounted within recess 25 of the tape measure 10 ″ by using adhesive coating 24 ′. The writing surface 20 is removably connected to the tape measure 10 ″ by the magnetic coupling between magnetic material 22 ′ and magnetic material 23 ′. While the magnetic material 22 ′ is secured to the writing surface 20 via adhesive coating 21 ′ it does not cover completely one surface of the writing surface 20 . The magnetic material is secured to the writing surface such that a lip 27 is formed. When the writing surface 20 is magnetically coupled to the tape measure 10 ″ removing is done by inserting a finger or tool into the gap 26 and grab the lip 27 .
FIG. 4 is an angled front view of the present invention in its smallest embodiment (B) applied on the smallest size of tape measure.
FIG. 5 is an angled front view of the present invention in its mid-sized embodiment (C) applied on a medium sized tape measure.
FIG. 6 is an angled front view of the present invention in its largest embodiment (A) applied on an extra large tape measure.
The foregoing disclosure and description of the invention is illustrative and exemplary therefore and various changes in the size, shape and materials, as well as in the details of the illustrated constructions may be made within the scope of the appended claims without departing from the spirit of the invention.
The corresponding structures, materials, acts, and equivalents of all elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
It should be understood that while the above and other advantages and results of the present invention will become apparent to those skilled in the art from the detailed description and accompanying drawings, showing the contemplated novel construction, combinations and elements herein described, and more defined by the appended claims, it is understood that changes in the precise embodiments of the herein disclosed invention are meant to be included within the scope of the claims.
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A removable reusable attachment tool having at least one magnetic component; an adhesive coating at least one surface of said at least one magnetic component, and a reusable writing component having a first surface securely affixed to said at least one surface of said at least one magnetic component by using said adhesive coating and a writing surface.
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REFERENCES TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 11/857,354 filed on Sep. 18, 2007, now abandoned, having the same title and common inventors with the present application, the disclosure of which is incorporated herein fully by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of automated systems for monitoring of resource usage and particularly to a system employing an interactive logic control with objective functions and constraint sets as inputs for real time status output with warning/alarm capability.
2. Description of the Related Art
Over-pumping of ground water is becoming more and more commonplace. This is especially true in arid regions of the Southwest United States. A recent GAO report claims that 36 states will encounter severe water shortages within only a few years. U.S. Government Accountability Office, Freshwater Supply: States' Views How Federal Agencies Could Help Them Meet the Challenges of Expected Shortages ,” GAO-03-514, July 2003, p 1). Since many water supply well fields are installed adjacent to areas of shallow surface water, significant impairment to adjacent riparian habitat can result from ground water extraction activities. Reduction in the ground water potentiometric surface due to over-pumping can induce leakage of the surface water body, thereby reducing the total amount of flow in rivers, streams, and springs. Stream flow reduction during fish migration seasons threatens the species survival potential. The methods covered in the patent application are applicable to predicting the effects of groundwater extraction on aquifer storage in general and on seawater intrusion in coastal aquifers.
Cooperative equilibrium arises when ground water users respect environmental constraints and consider mutual impacts, which allows them to derive economic and environmental benefits from ground water indefinitely, that is, to achieve sustainability. For cooperative equilibrium to hold, however, enforcement must be effective. Otherwise, according to the Commonized Costs-Privatized Profits (or CCPP) paradox, there is a natural tendency towards non-cooperation and non-sustainable aquifer mining, of which overdraft is a typical symptom. This would be exemplified by overdraft of a water-bearing zone adjacent to a river, thereby depleting the river of volume and ecologic functionality. Non-cooperative behavior arises when at least one ground water user neglects the externalities of his adopted ground water pumping strategy. In general, non-cooperative behavior results from lack of consideration regarding the interactions between the localized surface and ground water resources due to lack of information.
There is a significant need to better understand the ecological impacts due to ground water extraction activities adjacent to rivers, streams and springs. An automated interactive monitoring and modeling system will provide watershed managers with continuous understanding of the dynamic interactions between ground water extraction activities and surface water levels, and will allow for automated establishment of maximum allowable extraction thresholds based on minimum surface water level requirements, and therefore lead to optimization of ground water extraction activities while protecting the riparian habitat.
It is therefore desirable to provide systems and methods to optimize, monitor, and manage ground water resources based on the integration of sensors with computing capability incorporating an understanding of the ground water and surface water relationships. The methods of this patent application are applicable to predicting and controlling the effects of groundwater extraction on aquifer storage in general and seawater intrusion in coastal aquifers, also.
SUMMARY OF THE INVENTION
The present invention is a system for resource usage optimization employing an automatically controlled sensor suite providing data to a computer system for the analysis of spatial relationships of the sensors and resources. A control module incorporating an interactive logic, in an exemplary embodiment of well-stream coupled dynamic or game theory engines, operating in conjunction with the spatial data processing algorithms, GIS in an exemplary embodiment, receives as an input an objective function set for the use of the resource and constraint sets which are then monitored by the sensor suite. Incoming data is compared to the constraint sets and upon impact to any of the elements of the objective function set, creates a report/alarm for action or to trigger a corrective action.
In an enhanced embodiment, the sensor suite input data is provided to a constraint sets calculator for update of the constraint set assumptions for remodeling of interactive logic calculations. Tracking of input, output and relationships with thresholds over time is also accomplished.
As an exemplary embodiment, a system incorporating the invention is employed for well water monitoring on one or multiple wells drawn upon for either municipal or agricultural use by multiple users. The objective functions for the interactive logic modeling system allow maximizing the water withdrawal capability in the most economically efficient manner by multiple users while avoiding salt water intrusion into the well from overdraw conditions or exceeding a river water level minimum, the latter relying of coupled dynamic interaction algorithm for well-stream systems. The constraint sets preloaded into the model include response of the aquifer modeled from static data including historical permeability and storage capacity, flow rates and water table level history. The sensor suite monitors flow rate(s) and well level. In one exemplary embodiment, Game Theory employed as the interactive logic establishes the optimum flow rates for the desired economic maximization. Flow rate monitoring may be accomplished at both the withdrawal well and aquifer replenishment sources including monitoring wells surrounding the extraction well or feeding stream flow rates for update to the constraint data on flow rates, etc. Water table level (at the feed well and monitoring wells), river level, etc. data from the sensor suite is used to validate/update the constraints for the Game Theory for closed loop operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is a block diagram showing the physical elements of an exemplary embodiment and its functional control elements;
FIG. 2A is a block diagram of a first exemplary implementation for impact of multiple drawdown wells on a stream;
FIG. 2B is a profile of an exemplary river cross section and the distances from system wells;
FIG. 2C is a plan view of a reach of the exemplary river with calculation distances;
FIG. 2D is a detailed section view of the river cross section for water level monitoring with a multiple exemplary water level;
FIG. 2E is a profile of an exemplary river cross section and the distances from system wells with definition of partial wetted depth;
FIG. 3 is a block diagram of a second exemplary implementation for impact of multiple drawdown wells on a ground water table;
FIG. 4 is a flow chart of the operation of the functional control elements for a disclosed embodiment; and
FIG. 5A is an example simulated screen shot of the Graphical User Interface (GUI) presentation of a Well information summary entry and display screen;
FIG. 5B is an example simulated screen shot of the GUI presentation of a detailed well information entry and display screen;
FIG. 5C is an example of the location, rating curve and wetted width information for an example well;
FIGS. 5D-5F are examples of well data entered and displayed for a set of wells in an exemplary system implementation;
FIG. 5G is an example simulated screen shot of the GUI presentation of a graph settings page for the exemplary system implementation;
FIGS. 5H , 5 J, 5 K, 5 L, 5 M AND 5 N are example histograms for the well system of the exemplary system implementation for a selected time series;
FIG. 5P is an example line data graph for the well system of the exemplary system implementation;
FIG. 6 is a simulated screen shot of a summary screen with GIS data information and summary histogram plots; and
FIGS. 7A and 7B are a flow chart of an exemplary constraints calculator operation for the disclosed embodiments.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings, FIG. 1 shows the elements of an embodiment of the present invention. Field sensors 10 are placed at the various physical features which are to be measured such as wells, streams or aquifers. The sensors themselves may include such devices as flow meters, temperature sensors, pH sensors, dissolved oxygen sensors and level sensors which indicate the condition of the physical feature under study. By the nature of the desired system effectiveness, multiple physical features will be monitored resulting in multiple sets of field sensors. In most cases the field sensors will be remote from the control center generally designated as 12 which houses the control and reporting elements of the system and telemetric systems such as transmitters 14 at or near each physical feature and receivers 16 residing at the location of the control center. The representation in the drawings provides for radio transmission, however, in actual embodiments telemetry transmission approaches may be of any applicable form known to those skilled in the art. Automated control of the multiple sensor suites is implemented in exemplary embodiments as disclosed in U.S. Pat. No. 6,915,211 issued on Jul. 5, 2005 entitled GIS BASED REAL-TIME MONITORING AND REPORTING SYSTEM the disclosure of which is incorporated herein by reference.
A computer 18 for processing of the telemetered sensor data is provided including integrated Geographic Information System (GIS) capability or other automated spatial data processor for calculation of geographically dependent parameters based on location of the physical features. A display 20 is provided as shown in the figure and may include multiple physical display screens or elements distributed for monitoring and decision making based on system output as will be described subsequently. In addition to the display(s) or as an integral presentation on the display(s) a warning/alarm system 22 is provided. In alternative embodiments, automatic dialing of telecommunications devices such as cell phones or pagers is also accomplished.
An interactive logic control module 24 operates on the computer receiving sensor data 26 as processed. The control module operates based on input from constraint sets 28 which may include static data and response functions measured with respect to the physical features under study. The discussion of the embodiments disclosed herein emphasizes economic benefit, but most often will be set to physical tolerances such as threshold water levels in actual physical operations. Additionally, the control module incorporates in its operation objective functions 30 predetermined by the system user. These objective functions may include such elements as maximizing the economic benefit of the overall use of the physical features as will be described in greater detail subsequently. The control module provides alarm levels 32 for activation of the warning/alarm system based on the calculations performed. Additionally, the sensor data received is provided in certain embodiments as feedback 34 to update the constraint sets. Modeled and actual data is stored by the control module in storage 36 for constraints assessment and modification as will be described subsequently.
A first exemplary use of the system is demonstrated in FIG. 2 for monitoring the impact of multiple wells 40 , 42 and 44 in distributed locations where drawdown on the wells may impact a nearby hydraulically connected stream 46 . The system incorporates field sensors including flow rate and level sensors 48 a , 48 b and 48 c at each of the wells. A flow regulator 50 a , 50 b and 50 c at each well may be employed for control feedback as will be described subsequently. The system also incorporates field sensors associated with the stream including level sensors 52 , 54 and 56 located along the stream length. As shown, the field sensors provide their data to the control center system 12 .
The data provided for active monitoring by the field sensors and the constraint sets employed by the control module includes the locations (x, y) of the extraction wells in a geo-referenced coordinate system; stream layout in the geo-referenced coordinate system; transmissivity and storativity associated with the stream, wells and intervening geological formations; total streamflow at a given time (tracked via level monitoring), current water depth, temperature provided by the associated field sensors; channel and overbanks' roughness; stream cross section and longitudinal profile in the reach affected by the wells; pumping well characteristics; historical pumping rates; and immediate flow rates of the wells.
Objective functions input to the control module may include such elements stream depletion regulations as limitations to assure that the stream level remains above a safe threshold (habitat sustainability) during ground water extraction by the wells under study. The data collected is applicable for use in determining current use limitations and future expansion potential.
The control module calculates the fraction of each well's pumping rate drawn from the stream and calculates the total volume of streamflow draft from the multiple wells simultaneously. Based on the constraint data, the system then estimates maximum pumping rate(s) allowed given permissible streamflow depletion. This constraint data may be obtained through trial-and-error with multiple outputs possible from the control module. In an exemplary application, the system compares extraction rates to optimal rates and provides a data output.
In an exemplary system for this embodiment, rating curves and wetted width equations are employed for calculation of stream impacts. The rating curve equation employed in the embodiment is of the form:
Q=ad b
in which Q is the flow rate (in ft 3 /s or m 3 /s) at a specified cross-section in the river as represented in FIG. 2B ; d=the depth of water (feet or meters) at the level-monitoring location in the specified cross-section; a and b are fitting parameters that are determined based on surveyed cross-section. Note that the coefficient a, b vary as the system of units changes from customary US units (feet, pound, second) to metric system of units (meter, kilogram, second).
The depth of water d equals:
d=h−h R (2)
in which h is the absolute water level at the specified cross section above mean sea level and h R is the elevation of the stream bottom at the location where level monitoring takes place in the cross section.
The partial wetted width (w), as seen in FIG. 2B , of the river at a specified cross section depends on the depth of water d, also, and the equation for w is of the form:
w=cd f (3)
in which c and f are parameters determined by field surveying.
The shortest straight distance y* between the wetted bank of the river at the specified cross section and the well equals the total distance between the water-level sensor in the cross section and the well (y) minus w:
y*=y−w (4)
Equations of the type (1)-(4) for each river cross section where monitoring takes place are employed as a portion of the constraint sets for the system.
An exemplary equation to calculate the flow rate (q) captured by a well pumping at a rate (Q w ) a straight (shortest) distance y* from river cross section may employ solutions such as “Transient ground water hydraulics”, by Robert E. Glover, Dept. of Civil Engineering, College of Engineering, Colorado State University, 1974 for stream depletion by a well:
q = Q w 2 y * π ∫ 0 L ⅇ - ( x 2 + y * 2 4 T S t ) x 2 + y * 2 ⅆ x ( 5 )
with symbols defined below.
The equation for q given Q w , y*, time of elapsed pumping t, aquifer parameter α=T/S, where T is the transmissivity and S the storativity is.
0
≤
q
≅
Q
w
2
y
*
π
∑
j
=
1
j
=
5
L
2
w
j
F
(
z
j
)
<
Q
w
,
Q
(
6
)
For the equation, q equals zero when the depth of water (d) is zero. Also, q cannot exceed the pumping rate Q w nor the streamflow Q. The quadrature weights w j and evaluation points z j as defined by Karl F. Gauss, as referenced in Applied Numerical Methods , by Carnahan et al., 1969, McGraw Hal, are as shown in Table 1.
TABLE 1
Index j
Weight w j
Evaluation points z j
1
0.56888889
0.00000000
2
0.47862867
0.53846931
3
0.47862867
−0.53846931
4
0.23692689
0.90617985
5
0.23692689
−0.90617985
The function F evaluated at z j , or F(z j ) in equation (6), is as follows:
F ( z j ) = ⅇ - [ L 2 ( z j + 1 ) ] 2 + y * 2 4 α t [ L 2 ( z j + 1 ) ] 2 + y * 2 ( 7 )
Where L is the distance of influence upstream and downstream the cross section where the water-level monitoring is implemented. See FIG. 2C .
Equations (6) and (7) are then calculated by the system for each cross section where water-level monitoring occurs.
The effect of well influence superposition, as will be described in greater detail subsequently, is also assessed based on the locations of monitored wells along the stream.
Specification of flow requirement and maximum allowable pumping rate can then be determined based on various imposed constraints. As exemplary, velocity, temperature, oxygen regulations to preserve fish habitat may result in a minimum amount of streamflow, Q min , specified in a reach. The streamflow in the reach minus the amount of it captured by a nearby well (q) may not exceed Q min . At equality,
Q−q=Q min (8)
solving for q in equation (8) and then approximating q by the expression appearing in equation (6) produces the maximum pumping rate compatible with minimum fish-flow requirement:
Q
w
=
Q
-
Q
min
2
y
*
π
∑
j
=
1
j
=
5
L
2
w
j
F
(
z
j
(
9
)
The ability to introduce various constraint sets into the system models allows greater complexity in the stream profile to be considered. Using FIG. 2D which is exemplary of detailed streambed field surveying. The water width W of the water surface at a height h (shown as h 1 , h 2 , h 3 , h 4 or h 5 ) is given by:
W
=
∑
j
=
2
n
(
x
j
-
x
j
-
1
)
(
10
)
The wetted perimeter WP (the length of the bottom of the x-section under water on the plane of the Figure) is given by (with n=the number of river stations):
WP
=
∑
j
=
1
n
(
x
j
-
x
j
-
1
)
2
+
(
y
j
-
y
j
-
1
)
2
(
11
)
Wetted area (A) of the (vertical) x-section under water (with n the number of river stations):
A = 1 2 ( x n - x 1 ) ( y n + y 1 ) - 1 2 ∑ j = 2 n ( x j - x j - 1 ) ( y j + y j - 1 ) ( 12 ) Hydraulic radius R=A/WP (13)
Hydraulic depth D=A/W (14)
Depth of water at the water-level monitoring location d=h−y 4 (15)
At a water level at or below the top terraces as shown in FIG. 2D , levels h 1 or h 2 , the first and last stations are now coincident with the left and right intersections of the wetted perimeter by the water surface at h. The total number of stations is 7 in this example.
The water width W (of the water surface at h 2 ) is given (with n=7) by:
W
=
∑
j
=
2
n
(
x
j
-
x
j
-
1
)
(
10
)
The wetted perimeter WP (the length of the bottom of the x-section under water on the plane of the Figure) is given by (with the number of river stations n=7):
WP
=
∑
j
=
1
n
(
x
j
-
x
j
-
1
)
2
+
(
y
j
-
y
j
-
1
)
2
(
11
)
Wetted area (A) of the (vertical) x-section under water (with n=7):
A = 1 2 ( x n - x 1 ) ( y n + y 1 ) - 1 2 ∑ j = 1 n ( x j - x j - 1 ) ( y j + y j - 1 ) ( 12 ) Again, Hydraulic radius R: R=A/WP (13)
Hydraulic depth D=A/W (14)
Depth of water at the water-level monitoring location d=h 2 −y 4 (15)
With water level in the lowest part of the stream channel at height h 4 , the water width W (of the water surface at h) is given by (with n=3, the number of river stations), W is again calculated using equation (10). The wetted perimeter WP (the length of the bottom of the x-section under water on the plane of the Figure) is given by Equation (11) (with the number of river stations n=3). Wetted area (A) of the (vertical) x-section under water is given by equation (12) (with the number of river stations n=3) with variables R, and D given by equations (13) and (14), respectively Depth of water at the water-level monitoring location is give by
d=h 4 −y 2
At least five water levels (h) entertained in the exemplary system and for each of these the width (W), wetted perimeter (WP), wetted area (A), hydraulic radius (R), the hydraulic depth (D), and depth of water at the water-level monitoring station (d) are calculated. The water levels, h, are chosen to give a representative variation of the variables W, WP, A, R, D, and d as a function of water level rise.
Again calculating flow rates, from the Manning's equation for the exemplary embodiment, the flow rate Q (in m 3 /s) through the cross section is written as a power law in terms of the hydraulic depth (D) corresponding to an arbitrary water level h:
Q=a*D b* (18)
in which:
a * = 1 n W 5 / 3 WP 2 / 3 S f ( 19 )
and b*=5/3.
In equation (19) n=Manning's roughness coefficient which determined from field observations and provided as a constraint; W=water surface width corresponding to water level h; WP=wetted perimeter corresponding to water level h, these last two computable from equations given above (see equations (10) and (11), for example); S f is the friction slope or energy-tine slope. S f cannot be determined in general unless Q is known, which, in turn, is unknown in this application thus creating a circular and unbreakable chain of dependency. For this reason S f is approximated by the slope of the stream thalweg, which is the drop of elevation of the thalwed (ΔH) with distance measured along the thalweg (ΔL). ΔH and ΔL would be measured in the field to approximate the friction slope:
S
f
≅
Δ
H
Δ
L
(
20
)
To express the flow rate Q in terms of the depth of water at the water-level monitoring station by returning to equation (1),
Q=ad b (1)
a regression of values of D vs. values of d is conducted, where at least five pairs of values (d,D) are available from the calculations carried out for several water levels described above. A power law provides an accurate fit of D as a function of d:
D≅a 1 d b 1 (21)
Combining equations (18), (19), and (20) the flow rate Q is given by equation (1) with coefficients:
a=a*a b b* (22)
b=b 1 b* (23)
where a* is given by equation (19); b*=5/3, and a 1 , b 1 stem from the regression (21).
Recalling FIG. 2B and the previous description of the calculate the flow rate Q, the partial wetted depth w, and the capture of streamflow by a well, referring now to FIG. 2E , calculation of the partial wetted depth by the equation can be accomplished
w
=
W
-
W
*
=
[
∑
j
=
2
n
(
x
j
-
x
j
-
1
)
]
-
W
*
(
24
)
where
y*=y−w (4)
Recall that it is y* what is needed in the stream-well interaction equations.
Nevertheless, if desired, one can regress w against d from the pairs of values (w, d) that can be obtained from the calculations carried out for several water levels h. This produces an accurate power law expressing was a function of water depth d:
w=cd f (3)
which is one of equations appearing in the stream-well interaction algorithm previously discussed.
A second exemplary use of the system is shown in FIG. 3 wherein multiple wells 60 , 62 and 64 interact through a common aquifer. The aquifer properties are measured at draw down site 66 which may employ a monitoring well. As in the prior example, each well incorporates a field sensor set that includes at least a level sensor 68 a , 68 b and 68 c and flow meter 70 a , 70 b and 70 c which may be a pumping rate monitor. A flow regulator 72 a , 72 b and 72 c is employed for control feedback. The monitoring, well at the draw down site employs a field sensor set that includes a level sensor 74 and may include a flow meter with flow direction sensing in certain advanced embodiments. In alternative embodiments, when using the invention to protect from saltwater intrusion water level sensors are placed in several wells to determine the direction of flow near the salt-fresh water interface. If direction of flow is opposite to what is desired, this can serve as the tolerance modeled to in order to determine pumping logistics. The data from the field sensors is provided to the control center.
As previously described, the superposition of the effects of n nearby wells may be taken into account by the system. For implementation in one form of the exemplary embodiment, the system provides for n wells each with a constant pumping rate Q j , j=1, 2, . . . , n located in a confined aquifer that has transmissivity T and storativity S as previously described. The pumping in the wells cause a drawdown s 0 at a specified location 0 in the aquifer. An exemplary constraint provides the allowable maximum drawdown at the location 0 (draw down site 66 ) is s max .
The drawdown caused by well j at location 0 is determined in the exemplary embodiment by the equation as defined in Theis, Charles V. “The relation between the lowering of the piezometric surface and the rate and duration of discharge of a well using ground-water storage”. Transactions, American Geophysical Union 16: 519-524 (1935), hereinafter Theis (1935):
s ( r j ,t j )= a j Q
a j = W ( u j ) 4 π T j = 1 , 2 , … n ( 26 )
in which the dimensionless variable u j :
u j = r j 2 S 4 t j T ( 27 )
where r j is the distance from well j to the location 0 , and t j is the elapsed time since the j-th well started pumping. The well function W(u j ) is defined as follows:
W ( u j ) = - C - ln ( u j ) - ∑ m = 1 ∞ ( - 1 ) m u j m m ( m ! ) ( 28 )
where C=0.577125 . . . The well function is approximated in the calculation of drawdown by the following expansion to its fourth-order term:
W
(
u
j
)
≅
-
0.577125
-
ln
(
u
j
)
+
u
j
-
u
j
2
4
+
u
j
3
18
-
u
j
4
96
(
29
)
To obtain pumping rates Q j , j=1, 2, . . . , n that produce the allowable maximum drawdown at location 0 , the following objective function is minimized with respect to the pumping rates and β (β is a Lagrange multiplier):
Minimize
F
=
∑
j
=
1
n
(
a
j
Q
j
-
s
max
)
2
-
2
β
(
(
∑
j
=
1
n
a
j
Q
j
)
-
s
max
)
(
30
)
Equation 30 for F is differentiated with respect to the pumping rates Q j , j=1, 2, . . . , n and with respect to β, the resulting derivatives are equated to zero and solved with respect to Q j , j=1, 2, . . . , n and produce the following pumping sustainable pumping rates:
Q j = s max n a j j = 1 , 2 , … , n ( 31 )
in which a j is calculated as follows:
a
j
≅
-
0.577125
-
ln
(
u
j
)
+
u
j
-
u
j
2
4
+
u
j
3
18
-
u
j
4
96
4
π
T
(
32
)
Implementation in the exemplary embodiment is accomplished by entering the data: T, S, s max (r j , t j , j=1, 2, . . . , n) as constraints in the system.
The variables u j , j=1, 2, . . . , n are then calculated as
u j = r j 2 S 4 t j T ( 33 )
And the coefficients a j , j=1, 2, . . . , n are calculated as:
a
j
≅
-
0.577125
-
ln
(
u
j
)
+
u
j
-
u
j
2
4
+
u
j
3
18
-
u
j
4
96
4
π
T
(
34
)
The sustainable pumping rates for the wells are then calculated as
Q
j
=
s
max
n
a
j
j
=
1
,
2
,
…
,
n
(
35
)
A similar development for an unconfined aquifer is employed by the system using equations as defined by in Neuman, S. P., Analysis of pumping test data from anisotropic unconfined aquifers considering delayed gravity response, Water Resources Research, vol. 11, no. 2, pp. 329-342, (1975), hereinafter Neuman (1975).
FIG. 4 shows basic elements of data flow for the exemplary embodiments of the invention presented herein. Basic data 402 for aquifer and stream characteristics as well as regulatory and protection or threshold requirements are entered as constraint sets and objective functions as described for the various embodiment above. This basic data is exchanged interactively with the modeling theory 404 employed in the interactive logic control module as will be described in greater detail subsequently. Field sensors and other measurement sources from production wells, streams and monitoring wells respectively provide input data 406 , 408 and 410 to the interactive logic control module for data analysis and reporting, model calibration, model predictions and control 412 . Feedback 414 is provided to update the modeling theory, as will be described in greater detail with respect to FIG. 7 . Sensor data is entered into the model along with pre-measured values to determine amount of drawdown associated with each pumping well, then impact on the specific location (e.g., amount of water level reduction) is determined, upon which the data is plotted (e.g., as extraction rate versus sustainable extraction rate for that time step for each well). If a threshold is exceeded, this is displayed graphically and could be (but does not always have to be) integrated with a control module to reduce the extraction rate at a particular well that is pumping at an unsustainable rate. The output provided by the data analysis and reporting function is presented 416 for management decisions and recommendations including warning/alarms attributable to excess drawdown based on the constraint sets, objective functions and modeling theory. Active control 418 is implemented in advanced embodiments for automatic control of pumping rates or other affirmative output to well operators for required action. This could be in the form of automated e-mail advisories/directives or similar communications or automated reduction in pumping rates.
System interaction with the user for initial operating data and constraints input is accomplished using a Graphical User Interface (GUI) on display 20 with standard keyboard 21 or other input devices. For a system employing the first described embodiment for a stream/well interaction system, basic well identification is determined and entered into the system as shown in FIG. 5A on a Well Information page 500 . For the example traced herein three wells are employed, however, the system may handle large numbers of monitoring sites as will be demonstrated subsequently. Wells are identified in name blocks 502 and can be added, deleted or edited with control buttons 503 . Each name block has an associated position identifier 504 which is shown as latitude and longitude for the exemplary embodiment. This entry allows correlation with the GIS capability in the system.
For each identified well in the Well Information page an expansion page 506 as shown in FIG. 5B is available. In a location block 508 , latitude, longitude, and stream position are viewable/enterable. Stream position is an integer value, where 1 represents the most upstream position and each successive downstream well has its position increased by 1, the next downstream well has a value of 2, the next one is 3, and so on.
Constraint sets associated with each well are viewable/enterable. A rating curve block 510 includes values, A & B corresponding to a & b in equation (1). The wetted width block 512 includes values C & F corresponding to c & f in equation (2). The units can either be expressed in feet or meters. Aquifer values, storativity (S) and transmissivity (T) which are used in equation (5) are available in the Aquifer block 514 . For subsequent correction of constraints, as discussed with respect to FIG. 4 above and in greater detail subsequently with respect to FIG. 7 , a slider 515 is provided for the user to select or emphasize modification of the transmissivity (T) or storativity (S).
Distances block 516 provides the distance values for the well including the distance from stream bank (y*) for use in equation (4), the value for influence distance represented as L in equations 5, 6 & 7, and bank to sensor distance.
Values block 518 provides the water and bed elevation values used in equation (2) which calculates depth for comparison to the constraint of target depth. The target flow constraint is also provided. A target depth, or a target flow value may be employed to calculate the sustainable pumping rates. Either of these values can be used by the equations as described above. Volume units be expressed in gallons, liters, cubic feet, or cubic meters. Time units can be seconds, minutes, hours, or days. When the units are changed, the number is re-displayed for those units, while still corresponding to the same volume per time.
The last section is a pumping block 520 which provides operational data for pumping values associated with the well. The pump start date is used to calculate elapsed times, and the pumping rate may be entered and used in equation (6) as the value Q w . Pumping rates can be expressed in the same volume and time units as shown above.
The sustainable rate for the displayed well is calculated, as will be described in greater detail subsequently, when the calculate button 522 is pressed, and expressed in the same units as the pumping rate.
Demonstrating operation of the exemplary system using the three wells identified in the examples of FIGS. 5A and 5B , the same rating curve values are applied for each well and the rating curve 510 and wetted width 512 blocks with data that would be entered for each of the wells is shown in FIG. 5C . In actual practice individual wells will likely have different rating curves and wetted width data. Location data is not shown in FIG. 5C and may be manually entered for each well or my be automatically entered based on GIS data available.
The remaining data for the Aquifer block 514 , Distances block 516 , Values block 518 and Pumping block 520 for each of the three wells is shown in FIGS. 5D , 5 E and 5 F respectively. While certain data is the same, other data, notably transmissivity associated with each well, is different.
The GUI provides for display setup for the use with such parameters a Graph Settings page 522 shown in FIG. 5G . Graph settings include a plot date/time block 524 which allows selection of a range of dates for plotting, as will be described in greater detail subsequently. Graph axis information block 526 providing maximum values and units, threshold block 528 defining a value and visualization enablement, plotted sensors block 530 allowing selection of sensors to be viewed on the graphs and Sustainable histogram block 532 for visualization cues provide selection of the GUI output appearance for the user.
As defined for the example in the Graph Settings page of FIG. 5G , start & end dates for the plot, plot frequency, maximum Y axis values, colors for each well plot, sustainable values in the histogram are provided. Selection can be made to plot the data either in a line plot with values vs time, or a histogram where each well is shown in a bar graph along with the sustainable value, if desired.
For this example, all 3 wells are plotted in different colors, with a frequency of every 7 days. The sustainable value will be shown in yellow, and if the maximum sustainable value is exceeded, a red histogram for that well is shown. Histogram data is shown as selected in FIG. 5G .
The histogram data for the time periods is shown in FIGS. 5H through 5N . A slider bar 534 is provided in the GUI for the user to select the date to be displayed. For example FIG. 5H is the initial date in the data sequence, Feb. 9, 2008. Moving the slider button 536 to the right selects the next date, Feb. 16, 2008 for display of data as shown in FIG. 5J .
If the selected date has passed, then actual sensor data from the field sensors will be present allowing population of the data fields with actual data. However, if the date has not yet passed, actual data will be employed to the current date and the system modeling will then provide calculated values to populate the various fields through the selected graph date.
For this example, the pumping rates of Wells 1 & 3 are steady pumping at a rate of 5000, while well 2 starts out at 5000 cu/m per day, increases to 15000 for 2/23 and 3/2 and then drops back to 10000 for 3/9 and 3/16. This is clearly seen in the Line Plot shown in FIG. 5P where trace 538 is well 2 and traces 540 and 542 are wells 1 and 3 (overlapping with identical pumping rates).
The initial data histogram in FIG. 5H on Feb. 9, 2008 shows all three wells with actual pumping rates, bars 544 a , 544 b and 544 c well below calculated sustainable values 546 a , 546 b and 546 c . FIG. 5J for the next date of Feb. 16, 2008 shows identical pumping rates for the three wells. However, a slight decline in calculated sustainable rate 548 b for well 2 is shown. With the increase in pumping rate of well 2 , bar 550 b shown in FIG. 5K on Feb. 23, 2008 the sustainable rate is exceeded and the new calculated sustainable rate, bar 552 b is lower. Well 3 as down stream from well 2 is also now exceeding its sustainable rate, bar 552 c , even though it did not change its pumping rate. This demonstrates the superposition effects of the wells on one another as well as the stream. As shown in FIG. 5L with no change in pumping rates, wells 2 and 3 remain exceeding the sustainable rates. However, with a reduction in pumping on well 2 (not all the way back to its original value but to a value approaching the calculated sustainable rate of FIG. 5L ), FIG. 5M shows that the pumping rate of well 2 , bar 556 b , reducing to 10000 cu/m per day and the calculated sustainable rates for both wells 2 and 3 , bars 558 b and 558 c , respectively now exceed the actual rates.
A top level format for output such as that shown in FIG. 6 is provided as a portion of the GUI on display 20 for the exemplary embodiments which incorporates both the histogram format and GIS location information for visualization of the well system. A general digital map overview 602 such as that available in GIS systems of the aquifer/well or well/stream system is provided showing the location and physical relationship of the various elements such as wells 604 . Graphical data presentations 606 , 608 and 610 determined by the data analysis and reporting function are provided for each element, i.e. for each well. In the example shown, well 2 is exceeding its sustainable threshold with pumping rate 612 compared to modeled limitation 614 with warning/alarm functionality shown in, for example, a distinctive color such as yellow or red. Wells 7 and 8 have pumping rates 616 and 618 , respectively, which are within their modeled limitations or sustainable values 620 and 622 .
Alternative embodiments include additional decision support quality information integrated with controllers to automatically respond to conditions. For instance, if a groundwater extraction rate is deemed unsustainable based on model feedback, automatic the reduction in extraction rates is accomplished through a supervisory control and data acquisition (SCADA) system.
The disclosed embodiments provide for feedback 414 based on actual data received for correction of the modeling constraints as described previously with respect to FIG. 4 . As shown in FIG. 7 , initial predictions and modeling based on the constraints, the natural system parameters (such as transmissivity and storativity) and measured results are generated, step 702 , and are stored by the system. step 704 , as previously described. Measured data from the sensors is received, step 706 , and both measured and estimated water level distributions are generated, step 708 for specific time steps of interest. The GIS system allows interpolation of those measurements/estimates over an entire region of interest such as the water basin or stream well interaction system of the exemplary embodiments, step 709 .
While pumping rates have been employed for the exemplary description, water level and stream flow rates, in the stream/well interaction system and water level distributions in the water basin system, for example, are also measured by the sensors in the system not only at active wells but at measurement wells and other sites.
On a continuous basis, predetermined interval or upon selection by the user, a comparison of measured and estimated (modeled) water level distributions, flow rates and/or stream levels are compared to the predicted outcomes by the modeling, step 710 . A determination is then made if observations and predictions are in agreement within an acceptable error tolerance, step 712 . If so, then no changes are made to the constraints sets and modeling and data collection continues. For an exemplary embodiment, revision of constraint parameters would be effected whenever predicted values differ more than plus or minus 5% from measured values. The US Geological Survey, for example, considers measurements that are within plus or minus 5% of “truth” to be excellent and it is anticipated that expectations of field to be be any closer than that error threshold of 5% would be unreasonable.
If, however, observations do not sufficiently agree with predictions, substituting actual data into the Theis (1935) or Neuman (1975) model calculations described above for a selected time set for reverse calculation of one or more of the constraints, T and S as exemplary, is accomplished, step 714 . Validation of the revised constraints is then accomplished by comparison of newly calculated estimates with the revised constraints as compared to a selected time set of prior actual data, step 716 . Steps 714 and 716 may be iterated as needed to establish a match within acceptable tolerance of the modeled and actual data, step 718 . The adjustment of T and S for an exemplary implementation is based on the minimization of the sum of square deviations between measured values of withdrawn flow “q” and the theoretical equation for “q” given in equation (5) and that involves T and S. The minimization of the sum of squared deviations is done by nonlinear optimization in which, starting with values of T and S used in the previous period in which “q” was estimated, T and S are changed using a two-dimensional Newton-Raphson search method until convergence to optimal values of T and S is achieved. Selection by the user of an emphasis on T or S for creating convergence of the search method may be accomplished with controls such as that described with respect to FIG. 5B . The new constraints set is then imposed for future predictions, step 720 .
In one exemplary embodiment for the interactive control logic, an algorithm based on Game Theory such as that disclosed by Nash. J. F., “Equilibrium points in n-person games” Proceedings of the National Academy of Sciences of the U.S.A., 36, 48-491950 and Nash, J. F., “Non-cooperative games.” Annals of Mathematics, 54, 286-295, (1951) is employed to derive modeling strategies that would provide sustainability. General application of game theory is employed for competitive activities (games) in which each participating party chooses an individual strategy that affects all the other parties taking part in the game. The participants can be non-cooperative or cooperative. In a non-cooperative scenario each party chooses strategy which is best for itself, without regards to societal or someone else's welfare. In a cooperative scenario parties may act in unison to improve their joint payoffs.
As employed with respect to embodiments of the present system, non-cooperative usage is exemplified by overdraft of a water-bearing zone adjacent to a river, thereby depleting the river of volume and ecologic functionality. This scenario arises when at least one ground water user neglects the externalities of his adopted ground water pumping strategy. In general, non-cooperative behavior results from lack of consideration regarding the interactions between the localized surface and ground water resources due to lack of information. The embodiments disclosed herein specifically make information available which may eliminate non-cooperative operation.
For a cooperative scenario, equilibrium arises when ground water users respect environmental constraints and consider mutual impacts. This allows users to derive economic and environmental benefits from ground water and habitat indefinitely—sustainability. To obtain this result, information and an adaptive approach based on dynamic data tracking is required and can be supplied by the system disclosed herein.
More specifically, when aquifer properties and extraction well characteristics are known, the algorithm can be used to estimate the water level, or potentiometric surface, at any location within the domain of an investigation. This powerful concept allows a determination of pumping thresholds for single and multi-well extraction systems in order to maintain target water levels within a natural water-bearing system. A partial list of applications includes: stream and river stage protection, cooperative ground water extraction strategy development, and protection from seawater intrusion.
The objective functions are selected for the system based on cooperative and non-cooperative parameters and may, for example, be defined to maximize economic benefit to the well operators while maintaining sustainability of the aquifer or riparian system being monitored.
Applying game theory as the interactive logic control module modeling approach for n wells (n is an integer equal to or larger than 1) each extracting groundwater at a rate Q k , k=1, 2, 3, . . . , n. The quadratic linearly constrained game-theory formulation of groundwater extraction control results in a problem of the form:
Maximize Q T G Q+Q T z+c
w.r. t. Q
subject to: B Q<=b
in which Q is a vector of pumping rates, T denotes “transpose”, G is a matrix of optimizing coefficients, z is a vector of aquifer data values, and c is a scalar that depends on aquifer conditions. B is matrix of constraints, and b is a vector of regulatory values imposed on drawdowns.
This problem is solved for the vector of pumping rates Q, which comply with restrictions to be met at an impact location such as another well in an aquifer or a hydraulically connected stream as provided in the exemplary embodiments discussed above. Qk is then determined for each well by solving the quadratic problem state above. For the exemplary output defined in FIG. 6 , this calculated Qk is presented as the modeled limitation for each well while measured actual flow rates provide the comparison data as described. In the case of well-stream interaction, the algorithm to predict stream depletion is based on an analytical solution of the radial flow equation with a stream acting as a head-boundary condition
Having now described the invention in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present invention as defined in the following claims.
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A system for resource usage optimization employs an automatically controlled sensor suite providing data to a computer system for the analysis of spatial relationships of the sensors and resources. A control module incorporates an interactive logic, in an exemplary embodiment of well-stream coupled dynamic or game theory engines, operating in conjunction with the spatial data processing algorithms, GIS in an exemplary embodiment, receives as an input an objective function set for the use of the resource and constraint sets which are then monitored by the sensor suite. Incoming data is compared to the constraint sets and upon impact to any of the elements of the objective function set, creates a report/alarm for action or to trigger a corrective action.
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This is a continuation of U.S. application Ser. No. 08/992,645, filed Dec. 16, 1997, and now U.S. Pat. No. 5,839,500 which is a divisional application of U.S. application Ser. No. 08/221,213, filed Mar. 30, 1994, now U.S. Pat. No. 5,697,423, issued Dec. 16, 1997. The disclosures of U.S. Pat. No. 5,839,500 and U.S. Pat. No. 5,697,423 are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for improving the quality of metal castings. More particularly, the present invention relates to a method and apparatus for controlling the heat extraction of molten metal being cast in a continuous caster.
BACKGROUND OF THE INVENTION
The continuous casting of molten metal into ribbons, strips, sheets and slabs has been achieved through a number of processes, including, roll casting, belt casting and block casting. As used herein, the term "metal" refers to any number of metals and their alloys, including without limitation, iron, aluminum, titanium, nickel, zinc, copper, brass and steel. In general, continuous casters comprise a continuously moving mold to which molten metal is supplied. The term "mold," as used herein, includes any system of rollers, belts or blocks which are used to define a casting region in a continuous caster. Heat transfer from the molten metal to the mold at the metal/mold interface results in solidification of the metal. Physical characteristics of the cast metal, such as thickness, can be determined during casting by, among other things, the contact time of the metal with the mold surface and the temperature differential across the metal/mold interface.
For example, in a typical continuous block casting process used in the production of aluminum strip, such as that described in U.S. Pat. No. 3,570,586, by Lauener, assigned to Lauener Engineering Ltd., the block caster mold includes two counter-rotating, endless block chains. The block chains are comprised of a number of chilling blocks, referred to herein as "blocks," which have been linked together. Each block chain is formed into an oval "casting" loop by placement on a track. As the blocks travel through the casting loop, the blocks in each chain are forced together in the casting region to form a flat plane, continuous mold. The block caster can further comprise a side dam system for preventing the metal being cast from escaping the mold by travelling in a direction transverse to the casting direction. In other embodiments, the blocks themselves may be designed with ridges to prevent molten metal from escaping the mold cavity. Heat transfer from the molten metal to the blocks results in solidification of the metal.
It is desirable when continuously casting molten metal to be able to control the quality of the metal being cast. The term "quality," as used herein, when referring to the metal being cast, refers to measurable characteristics of a metal cast, including, but not limited to, the number of surface imperfections in the cast, the microstructure of the cast, or the width and thickness of the cast. One method for controlling the quality of the cast in a continuous caster is to control the heat extraction rate of the metal being cast. The term "heat extraction rate," as used herein, refers to the rate of heat extraction from the molten metal in Watts. One way to control the heat extraction rate of the metal being cast is through cooling the mold surfaces in contact with the cast.
It can be difficult, however, to design a system for cooling a mold in a continuous caster because the mold is always in motion. Moreover, it can be difficult to control the complex, three-dimensional thermal loading of a mold. The cooling of mold surfaces should be carefully controlled to prevent undesirable thermal shocks and undesirable thermal loading of the mold from affecting the cast and causing unnecessary wear to the mold. Thermal shocks experienced by the mold as it cycles through the casting process and is repeatedly heated and cooled can cause fatigue stress resulting in premature wear of the mold, necessitating replacement. Moreover, undesirable thermal loading of the mold can cause residual heat to remain trapped in the mold. Residual heat remaining in the mold can prevent it from reaching its maximum heat extraction rate potential. Careful control of the mold cooling can reduce the formation of cold edge cracks in the cast. Careful control of the mold cooling can also prevent the formation of other imperfections that reduce the quality of a cast.
Several U.S. patents describe fluid cooling systems for use in continuous casters. For example, U.S. Pat. No. 4,934,444, by Frischknecht et al., and U.S. Pat. No. 3,570,583, by Lauener, both assigned to Lauener Engineering Ltd., disclose apparatus used in cooling molds of continuous casters. The apparatus consist of enclosures disposed in close relation to the molds, wherein cooling fluid is sprayed by nozzles to contact mold surfaces. The heated cooling fluid is collected in the enclosures and a vacuum atmosphere prevents cooling fluid from escaping from the enclosure. The mold surfaces can also be dried using forced air upon exiting the cooling enclosure.
U.S. Pat. No. 4,807,692, by Tsuchida et al., assigned to Ishikawajima-Harima Jukogyo Kabushiki Kaisha and Nippon Kokan Kabushiki Kaisha, discloses an apparatus for use in cooling the blocks of a continuous block caster. Tsuchida et al. disclose a cooling apparatus for blocks, wherein the blocks contain cavities which extend through their length in the direction transverse to the casting direction. A system of reciprocating nozzles aligned with the cavities in the blocks deliver cooling fluid to the blocks. The used cooling fluid is collected on the opposite side of the caster.
Known cooling systems typically use "flushing" processes for supplying cooling fluid to the heated mold surfaces. In a flushing process, large volumes of cooling fluid are brought into contact with the mold surfaces, typically by spraying the cooling fluid under pressure. Flushing processes alone, however are generally undesirable because such processes are difficult to control. For example, the cooling fluid can contain bubbles which contact the mold surface, creating uneven heat transfer across the mold/fluid interface. This can cause undesirable thermal shocking and undesirable thermal loading of the mold. Moreover, flushing systems are typically hand controlled and can be difficult to rapidly and repeatedly adjust in response to changes in the casting parameters, such as casting temperatures and cast quality, for example.
SUMMARY OF THE INVENTION
The present invention provides methods and apparatus for improving the quality of metal castings. The present invention provides methods and apparatus for cooling molten metal being cast in a continuous caster. The present invention provides methods and apparatus for controlling the thermal loading of a mold in a continuous caster. The present invention provides methods and apparatus which extend mold life in a continuous caster by reducing fatigue stress and premature wear of the surfaces of the mold. The present invention provides methods and apparatus for closed-loop control of the quality of metal being cast in a continuous caster.
In accordance with the present invention, apparatus are provided for cooling a mold used to solidify molten metal which utilize multiple cooling stages. Apparatus are also provided which allow control over the cooling of a movable mold in the casting direction (the "x-direction") and the direction transverse to the casting direction (the "y-direction").
In accordance with the present invention, apparatus are provided for measuring casting parameters for use in control of cooling, cleaning and coating of a mold in a continuous caster. Such casting parameters include mold temperatures, cast temperatures, melt temperatures, mold surface condition and cast quality.
In accordance with the present invention, apparatus are provided for cooling, cleaning and coating of a movable mold in a continuous caster. Mold cooling is preferably accomplished through contacting a thermally loaded mold surface with cooling fluid in droplet form. Such apparatus are capable of being automatically controlled to control cast quality without the need for human intervention.
In accordance with the present invention, methods are provided for use of the apparatus of the present invention. In particular, methods are provided for cooling, cleaning and coating a movable mold in a continuous caster. Moreover, methods are provided for controlling the cooling, cleaning and coating of a movable mold in a continuous caster. Such methods can be used for automatically controlling cast quality without the need for human intervention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical representation of the change in surface temperature of a chilling block in a known continuous block caster as it travels through a single casting cycle.
FIG. 2 is a graphical representation of the heat extraction obtained by a block in a single casting cycle using a known continuous block caster.
FIG. 3 is a graphical representation of the change in surface temperature of a chilling block in a continuous block caster using one embodiment of the present invention.
FIG. 4 is a graphical representation of the heat extraction obtained by a block in a single casting cycle using one embodiment of the present invention in a continuous block caster.
FIG. 5 illustrates one embodiment of the apparatus of the present invention for controlling the quality of a metal being cast in a continuous block caster.
FIG. 6 illustrates one embodiment of the present invention directed to placement of temperature sensors embedded in a chilling block of a continuous block caster.
FIGS. 7a through 7c are a block diagram illustrating one embodiment of the method of the present invention for controlling the quality of metal being cast.
DETAILED DESCRIPTION
The present invention relates to novel methods and apparatus for increasing the quality of metal being cast in a continuous caster. As used herein, the term "metal" refers to any number of metals and their alloys, including without limitation, iron, aluminum, titanium, nickel, zinc, copper, brass and steel. The present invention also relates to novel methods and apparatus for decreasing mold wear in a continuous caster. In particular, the present invention relates to mold cooling methods and apparatus which provide for more uniform control of the thermal loading and reduced thermal shocking of the mold. The present invention can also include mold cleaning and coating methods and apparatus. In addition, the apparatus of the present invention can be capable of closed loop control.
Control of mold wear and the quality of metal being cast can be achieved through control of the mold cooling process used to solidify the metal cast. In general, to increase mold life, it is desirable to reduce thermal shocking, particularly at the mold's surface. In general, it is also desirable to control the thermal loading of the mold to allow the mold to reach its heat extraction rate potential by efficiently extracting heat throughout the mold.
Thermal shocking occurs when a mold experiences rapid changes in temperature, for example, as a result of molten metal contacting the casting surface of a mold. Thermal shocking can be most severe in the casting region and during cooling of the mold. Known cooling methods and apparatus can cause undesirable thermal shocking of the mold as the mold travels through the casting cycle. As used herein, the term "casting cycle" refers to one complete revolution of a casting loop. While thermal shocking cannot be completely eliminated, thermal shocking can be reduced to assist in preventing the formation of stresses in the mold which exceed the limits of the mold material properties, i.e., causing the formation of stress fractures in the mold surface, requiring that the mold be replaced.
Thermal shocking (and uneven thermal loading) in a mold can be observed as rapid fluctuations in the mold's surface temperature and as steep temperature profiles below the surface of the mold in the "z-direction", i.e., the direction normal to the casting surface of the mold. Thermal shocking has been observed to be the greatest, however, at the casting surfaces of the mold which interface with the molten metal in the casting region and the cooling fluid in the mold cooling system. In a typical casting cycle, a mold comes into contact with molten metal causing the surface temperature of the mold to rise sharply. As the mold travels through the casting region and is in contact with the solidifying metal, the surface temperature of the mold peaks and then begins to decrease. The thermal shock experienced by the mold surface when it first encounters the molten metal can be transmitted through the mold thickness, and becomes dampened as the thermal shock "wave" penetrates deeper into the mold in the z-direction. Thus the mold begins to warm throughout its thickness as it extracts heat from the molten metal. As the mold leaves the casting region, the mold surface begins to cool.
As the mold surface encounters the cooling region and is flushed with cooling fluid, the mold surface temperature rapidly decreases. The rapid decrease in mold surface temperature establishes another steep temperature profile in the mold extending from the surface of the mold through its thickness. As heat is extracted from the mold at its surface, the heat distribution in the mold below the surface changes to establish equilibrium. In known cooling apparatus which use a number of rows of nozzles to spray cooling fluid on the mold surface, the temperature of the mold surface has been observed to rise and fall sharply as the mold leaves one cooling zone established by one row of nozzles and begins to enter another cooling zone established by another row of nozzles. These thermal shocks can be detrimental to the mold, resulting in mold wear and mold surface cracking.
The subsurface, z-direction temperature profile in a mold, particularly in thicker molds, such as chilling blocks in a block caster, is three-dimensional. The temperature of a mold can be observed to vary in the casting direction (the "x-direction") as the mold travels through a casting cycle and alternately makes contact with the molten metal and the cooling fluid. The mold temperature also varies in a direction transverse to the casting direction (the "y-direction"). In particular, the temperature measured near the centerline of the mold surface can be generally higher than the temperature measured near the outer edges of the mold surface. This "horizontal" change in temperature with position in the y-direction can result in the undesirable cast quality, such as formation of varying microstructure in the cast in the y-direction. To the inventors' knowledge no known mold cooling system addresses the need to control cooling of the mold in a continuous caster in both the x-direction and the y-direction. Control over cooling of the exterior of the mold in the x-direction and the y-direction (along the casting surface) allows control over the thermal loading through the thickness of the mold, i.e. in the z-direction.
The temperature profiles of molds observed in known casters in the x, y and z-directions are indicative of uneven and inefficient thermal loading of the mold as the mold travels through the casting cycle. Because thermal shocks are transmitted from the interface of the casting surface through the thickness of the mold, it is difficult to completely eliminate uneven thermal loading. Thermal loading, however, can be controlled by controlling thermal shocks to reduce internal fatigue stresses generated in the mold, and to increase the potential of the mold for extracting heat from the cast.
The present invention includes a novel method and apparatus for reducing the rapid increases and decreases in temperature experienced at the block surface to reduce fatigue stresses developed in the mold, and to reduce block wear. In one embodiment of the present invention this can be accomplished by controlling the rate of heat transfer to the mold surface while it is in contact with the molten metal and controlling the rate of heat transfer from the mold during cooling. In addition, the amount of heat extracted by the mold during continuous casting and the amount of heat extracted from the mold during cooling can be controlled to achieve steady-state, continuous casting.
Heat transfer to and from a mold in a continuous caster can be complex as it is dependent upon numerous variables. In general, the heat extraction of a mold in a continuous caster can be controlled by manipulation of the temperature, composition and volume of the cooling fluid brought into contact with the mold surfaces.
The temperature of the cooling fluid can impact the rate of heat transfer which occurs when the cooling fluid is brought into contact with the mold surfaces. The greater the temperature difference across the mold/fluid interface, the greater the driving forces can be for heat transfer. While it can be desirable in some instances to achieve a large temperature differential across the mold/fluid interface, such large temperature differential can also result in undesirable thermal shocking of the mold. In general, it is desirable to promote a temperature differential which allows for rapid heat transfer, but which does not allow for heat transfer to occur at such a rate as to cause undue thermal stressing of the mold. For example, for many aluminum alloy continuous casting operations utilizing block casters, the temperature differential between the surface of the mold and the cooling fluid will be less than about a few hundred degrees centigrade. Such temperature differentials, however, can vary depending upon the continuous caster, mold geometry and metal being cast.
For controlling cooling fluid temperatures, the apparatus of the present invention can include a heater or similar device. In addition, the apparatus of the present invention can include devices such as valves or the like for controlling relative amounts of cooling fluid at different temperatures which can contact the mold. In a preferred embodiment of the present invention, such valves can be controlled to manipulate the temperature of the cooling fluid in both the x and y-directions along a mold's casting surface. Control over cooling of the exterior of the mold in the x-direction and the y-direction (along the casting surface) allows control over the thermal loading through the thickness of the mold, i.e. in the z-direction.
The rate of heat transfer from the mold surface to the cooling fluid can also be dependent upon the cooling fluid composition. In general, the cooling fluid used in the mold cooling stages can be any fluid which allows for substantially unimpeded heat transfer from the mold. In some applications, however, it can be desirable to use cooling fluids which retard heat transfer from the mold. Preferably, the cooling fluid should not be a material which can be easily ignited or combusted. Further, it is preferred that the cooling fluid be nontoxic, non-abrasive and non-corrosive for ease in handling and to prevent damage or wear to mold surfaces. The most commonly used cooling fluid is water, however, it is contemplated by the inventors that any number of fluids which possess the required cooling fluid characteristics can be used satisfactorily in the present invention. It is also contemplated that additives can be included in the cooling fluid which can enhance or retard the ability of the fluid to transfer heat away from mold surfaces in the cooling region.
The rate of heat transfer can also be controlled by controlling the volume and form of delivery of the cooling fluid that comes into contact with the mold surfaces. In one embodiment of the present invention, the cooling fluid can be applied to the mold surface in droplet form rather than as a stream, such as in known cooling processes. While not intending the present invention to be constrained by theory, it is believed by the inventors that surprisingly, application of cooling fluid in droplet form reduces the average thermal stresses in a mold during cooling, reducing mold surface cracking, for example. On a microscopic scale, it is believed that contacting a mold's surface with cooling fluid in droplet form creates small zones of thermal stress, while leaving other, uncooled and unstressed zones which are not in contact with the cooling fluid. The combination of such stressed and unstressed zones results in an overall average thermal stress of the mold which can be less than that created by known cooling fluid flushing systems.
The average thermal stress experienced by the mold can be controlled, for example, through manipulation of cooling fluid droplet size, droplet distribution or the contact angle of the fluid with the mold surfaces. In general, to achieve favorable results, the diameter of the cooling fluid droplets can be below about 4 mm, and such droplets should be uniformly distributed across the mold surface. The droplet size used, however can depend upon the casting operation, and typically the droplet size will vary within a range for any particular casting operation. For example, in the casting of aluminum alloy slab utilizing a block caster, it has been found desirable to utilize droplet sizes within the range of about 50 microns to about 500 microns in diameter. Droplet sizes in excess of 4 mm, however, can be used successfully in the present invention depending upon, for example, the mold surface geometry and material and the type of metal being cast. As the temperature differential across the fluid/mold interface decreases during mold cooling, greater amounts of cooling fluid, i.e., fluid in larger droplet sizes or in streams under high pressure, or greater flowrates can be supplied to the mold surface without substantially increasing the average thermal stress experienced by the mold.
In one embodiment of the present invention, the heat extraction of the mold in a continuous caster can be accomplished gradually through the use of multiple cooling stages rather than in a large, single stage such as in known cooling systems. The use of multiple cooling stages can allow better control over cooling fluid temperature, volume, droplet size and contact angle. For control over mold cooling in the x-direction, each cooling stage can be independently manipulated to achieve a desired cooling effect.
A typical cooling stage in the present invention can include an enclosure containing an arrangement of nozzles or the like which deliver cooling fluid to the moving mold assembly in a continuous caster. Depending upon the requirements of each cooling stage, the cooling fluid can be provided at varying pressures and flowrates to the surfaces of the mold. Preferably, the stages can be designed to establish a substantially equal distribution of cooling fluid along the mold so that there are no uncooled gaps in which thermal shocks can form. In another embodiment, the cooling stages can be designed to control the rate of heat transfer along the x and y-directions of the mold surface, for example, by allowing independent control over fluid temperatures and flowrates in nozzles in the x and y-directions of a cooling stage. In addition to containment of the cooling fluid, the enclosures can also provide a means for collection of used cooling fluid, which can be cleaned, recycled and reused. The use of an enclosure also allows use of a vacuum atmosphere to collect water vapor created through cooling of the mold surface. Collection of water vapor can be important because it prevents the release of energy by the water vapor in changing phase to a liquid state from being transferred to fresh cooling fluid, which can reduce the effectiveness of the cooling system.
The various mold cooling stages can be placed in a variety of locations and configurations throughout the caster. In a typical continuous caster, however, such as a block caster having two horizontal casting loops, the cooling stages can be located opposite the casting region in both the upper and lower casting loops. The number of cooling stages used in a caster can depend, among other things, upon the type of continuous caster, the metal being cast and the desired amount of heat to be extracted from the mold during cooling.
Reduction in thermal shocking can also be achieved by controlling heat transfer between the mold surface and the molten metal in the casting region of the caster, as long as such control does not conflict with the heat transfer requirements for obtaining the desired cast quality. For example, in a block caster, subsequent to a chilling block leaving the cooling region, a coating can be applied to the surface of the block for controlling heat transfer from the molten metal to the block. The coating can retard heat transfer from the molten metal in contact with the blocks' surfaces to reduce thermal shocking. Such coatings should be non-combustible, have good adhesion to the mold surface, should be easy to apply to the mold surface, and should not substantially negatively impact cast quality. Preferably, such coatings can also be non-toxic, non-abrasive and non-corrosive for ease in handling and to prevent damage or wear to mold surfaces. In the continuous casting of aluminum using a continuous block caster, for example, it is known to apply an Edelweiss blackwash composition to the cooling fluid as a mold coating for slowing the rate of heat transfer along the mold/molten metal interface. The Edelweiss blackwash, which consists of an aqueous dispersion of amorphous, highly dispersed silicon dioxide (SiO 2 ) with about 1 percent of highly dispersed aluminum oxide (AlO 2 ), can be added to the cooling fluid and deposited on the casting surface of a chilling block as the block leaves the cooling region and the cooling fluid is evaporated or dried from the block surface.
A coating can also be applied to the mold after cooling using an atomizing sprayer or the like which can deposit the coating as a mist or fine dispersion of coating material particles, for example. As used herein, the term "fine" when referring to particle or droplet size refers to particles having a diameter of less than about 1.5 mm. For example, an air atomized sprayer can provide particles of coating material in the range of from about 30 microns to about 200 microns, and a pressure atomizing sprayer can provide particles of coating material in the range of from about 1 mm to about 100 microns. Other types of coating processes, however, including, but not limited to, roll coating, electrostatic coating, and other dry particle coating methods can also be used. Moreover, if a surface coating is applied to the mold, a drier or the like can be used for drying the coating on the mold surfaces. By impeding heat transfer, Edelweiss blackwash and other such coatings can reduce the rapidity at which the temperature at the mold surface rises, thereby reducing thermal shocking of the mold.
For control and monitoring of heat extraction of a continuous caster mold and the continuous cast produced, temperature sensing devices can be incorporated into the caster. The effectiveness of the cooling system in controlling thermal shocks and thermal loading of the mold can be monitored using temperature sensors, such as thermocouples and the like. For example, the total heat extracted from the cast by the mold can be calculated by measuring temperature changes throughout the mold during a casting cycle. Also, the cooling requirements for the caster can be calculated from such measurements. In this manner, the heat extraction rate of the molten metal can be maintained within an acceptable range of a desired heat extraction rate.
In order to measure mold temperatures as well as other temperatures throughout the caster, temperature sensing devices can be placed in both fixed and movable positions throughout the caster. For example, temperature sensors for monitoring cast temperatures can be placed in fixed positions at the exit points of the casting region. In addition, fixed temperature sensors can be placed at the entrance and exit points to each cooling stage to measure block temperature, and in the tundish to measure melt temperature. Thermistors or thermocouples, for example, can also be embedded in the rollers, belts or chilling blocks which comprise the movable mold in a continuous caster. Embedded temperature sensors are useful for measuring the temperature of the mold at various points in the z-direction and/or the y-direction throughout the mold. If embedded temperature sensors are used for temperature measurement, typically a telemetry device, such as a transmitter or the like, can be employed for receiving and transmitting the temperature measurements to a controller or operator for use in the control of the cooling process.
In a preferred embodiment of the present invention, temperature sensors can be placed in fixed positions throughout the caster and can be embedded in the mold itself. The number of temperature sensors used can vary depending, among other things, economic constraints and the information desired for controlling the casting operation. For example, for measuring temperatures in a continuous block caster having two horizontal casting loops, 9 fixed temperature sensors and 24 movable, embedded temperature sensors can be used in controlling mold cooling. In such a configuration, 3 fixed sensors measure the cast's surface temperature in the y-direction as the cast exits the casting region of the caster and the other 6 fixed position temperature sensors (3 for each of the two casting loops) can be used for measuring the surface temperature of blocks in the y-direction after the blocks exit the cooling stages. Typically, the 24 embedded temperature sensors (12 embedded in each of the two casting loops) are embedded in a single chilling block and/or support beam for measurement of temperatures in the y-direction and z-direction of the block and/or support beam.
In addition to controlling mold cooling, the present invention can include methods and apparatus for reducing mold wear and increasing cast quality through reducing the amount of unwanted matter and debris on surfaces of the mold that can come in contact with the molten metal being cast. Small amounts of debris can be deposited on the casting surface of the mold as pert of the casting process. In some continuous casting processes, used mold coatings can leave debris on the casting surfaces of the mold. Unwanted matter on the casting surfaces of the mold can interfere with the heat transfer between the mold and the cast and/or cooling fluid and can cause surface imperfections in the cast. To substantially minimize reduction in cast quality due to the collection of unwanted matter on the casting surfaces of the mold, the mold surfaces should be kept substantially clean and relatively free of unwanted matter. Thus, the present invention can include methods and apparatus for control of unwanted matter on the casting surfaces of a mold in a continuous caster, i.e. one or more mold cleaning stages. A cleaning stage in a continuous caster can include, for example, one or more copper or brass brushes arranged in an enclosure to contact the casting surfaces of the mold to dislodge and contain undesired matter from the casting surfaces of the mold. Such cleaning stage can also include apparatus for providing fluid at high pressure to the casting surfaces of the mold and/or apparatus for vacuuming the mold surface for removing dislodged debris. Cleaning of the mold casting surfaces during operation of the caster can be accomplished in one or more stages separately from the mold cooling steps or can be integrated with one or more cooling stages. It is preferred however, that cleaning of the mold casting surfaces be integrated with one or more cooling stages, particularly if a high pressure fluid cleaning stage is used and any cleaning fluid used is the same as, or is compatible with the cooling fluid.
Cast quality monitoring and mold surface condition monitoring can be used to control the mold cooling and cleaning processes of the present invention. For example, the imperfections in the cast and the debris on mold surfaces can be monitored to determine the effectiveness of the cooling and cleaning apparatus. In response to measured cast quality and/or mold surface condition, determinations can be made whether to adjust the cooling and/or cleaning steps in the methods and apparatus of the present invention. In this manner, monitoring the quality of the cast allows for feedback control of the cooling and cleaning systems.
The quality of the cast can be visually or optically inspected as the cast exits the casting region of the caster. Many imperfections, such as surface porosity, inclusions and breakouts in a cast can be optically measured. The term "breakouts," as used herein, refers to a cast condition which can result from insufficient heat extraction resulting in cracks in the exterior of the cast through which molten metal can flow. The cast can be optically monitored, for example, by an operator of the caster who can view the surface of the cast as it exits the casting region of the caster. Alternatively, the cast surface can be optically measured as it exits the casting region using photographic or closed circuit video devices or the like. For example, a video camera can be used to optically examine the cast under both bright and dark fields as it exits the casting region of the caster. The images recorded by such camera can be digitized, such as through the use of a data processing device, and the microstructure and imperfections in the cast surface can be examined to determine the quality of the cast. The casting surfaces of the mold can be optically inspected in a similar manner for monitoring mold wear, such as surface cracking, or for the presence of unwanted debris. In a preferred embodiment of the present invention, the information obtained by measuring the cast quality or inspecting mold surfaces through optical or visual means can be used for feedback control of the continuous caster.
The number of optical monitoring devices used in a caster can depend upon numerous factors, including, for example, economic considerations. In one embodiment, at least about 1 video camera or the like can be used for optically monitoring the quality of the cast and/or inspecting the mold surfaces. In a preferred embodiment, a plurality of video cameras or the like can be used to monitor the quality of the cast and/or to monitor the surface condition of the mold. For example, in a continuous block caster having two horizontal casting loops, 2 video cameras can be used to optically measure the quality of the cast strip as it exits the casting region of the caster (one for each of the two major surfaces of the strip), and 2 video cameras (one for each of the two casting loops) can be used to monitor the surface condition of the chilling blocks.
The operation of the caster, including any cooling and cleaning apparatus, can be controlled from a controller device or the like. A typical controller suitable for use in the present invention can include a user interface, and a data processor, for example, a microprocessor. The controller can be capable of manual operation of the caster controls in response to user/operator signals and automatic operation of the caster controls in response to the data processor. Data obtained by measuring casting parameters, such as cast quality and casting temperatures can be used in automated or manual control of the continuous casting operation. Moreover, a continuous stream of information can be received and manipulated by the microprocessor for controlling the operation of the caster. In a preferred embodiment, the control system can be capable of feedback control of the caster for modifying the quality of the cast. In a more preferred embodiment, the controller can be capable of closed-loop control of the caster, including, for example, the mold cooling apparatus.
In the method of the present invention, settings for caster controls can be manually preset to obtain a desired heat extraction rate from the molten metal in both the x-direction and the y-direction. As the caster is started, molten metal can be supplied from a tundish to a moving mold of a continuous caster. As the molten metal moves through the mold, sensors can measure the quality of the cast and various casting parameters, such as temperatures. The data obtained from such measurements can be received by a controller which can be capable of manipulating the data and altering caster controls to obtain a desired cast quality.
In one embodiment of the present invention, after the caster is placed into operation, optical inspections can be made of the cast surface and the surfaces of the mold. Data obtained from these inspections can be used to determine cast surface quality and mold surface condition. These measurements can be analyzed to determine if they are within acceptable ranges of desired values. If the cast surface quality and the mold surface condition are acceptable, the caster controls typically will remain unchanged. For example, the mold cleaning steps will not be modified if the amount of unwanted debris on the mold surfaces is acceptable.
If, after optical inspection, either the cast surface quality or the mold surface condition are not acceptable, a determination can be made, either by the caster operator or the data processor, whether the molten metal is castable. If the metal is not castable, for example, the molten metal cannot be solidified at a rate to prevent failure of the metal upon leaving the casting cavity, the casting operation can be halted. If the metal is castable, but requires that one or more casting parameters (i.e. heat extraction rate, etc.) be modified to obtain the desired product, the controller can alter the caster controls to obtain such casting parameters. For example, the heat extraction rate of the cast can be altered, such as, by changing the interface conditions where the molten metal contacts the casting surfaces of the mold. More particularly, in a continuous block caster, the Edelweiss blackwash coating on the casting surfaces of the chilling blocks can be modified to retard or increase heat transfer from the molten metal to the mold at the metal/mold interface.
In another embodiment of the present invention, temperatures can be measured throughout the caster for controlling the operation of the caster. In a preferred embodiment of the present invention, both optical and temperature measurements can be taken during casting for controlling the operation of the caster. For example, mold temperatures can be measured during casting in the x-direction (throughout the caster), the y-direction, and the z-direction (embedded in the mold). Temperatures can also be measured in the tundish, and at the cast surface as it exits the casting region. In general, the data gathered from the measurement of such temperatures provides information for controlling the operation of the caster. For example, slopes of temperature change curves (temperature profiles) can be calculated to determine if heat extraction of the cast or the mold through cooling are occurring too rapidly or too slowly.
If the measured cast quality is acceptable, the temperature data can be used to determine whether caster controls can be changed to improve the cast quality and mold cooling. For example, from the temperature measurements taken, the heat extraction requirements for mold cooling can be determined and calculated for each casting cycle in order to reach steady-state casting. To determine the total heat extracted from the cast or from the mold by the cooling system, a heat balance can be calculated which requires calculation of the heat flux. Determination of slopes of plotted temperature curves (temperature profiles) allow calculation of the heat flux using the following approximation if the thermal conductivity of the mold, i.e. the chilling block material in a block caster, is known: ##EQU1## Also, average mold temperatures and trends in mold temperature changes can be tracked and analyzed as changes are made to the mold cooling system. Mean temperatures can be calculated to determine if over-heating or over-cooling of the mold is occurring. In this manner, the mold cooling control settings which provide the most desirable cast quality can be defined and tested through experimentation with various casting parameters. Such casting parameters include, but are not limited to, the metallostatic pressure in the tundish, the incoming molten metal temperature, the cooling fluid temperature, pressure or flowrate, the gap between the upper and lower mold surfaces, the mold surface condition and the mold speed of the caster.
If the slab quality is determined to be unacceptable, but castable, casting parameters can be modified. For example, mold cooling can be modified by changing the cooling fluid flowrate, temperature and/or composition flowing through individual nozzles (or rows or columns of nozzles) in one or more cooling stages. After changes are made to the caster controls as a result of measurements taken during casting, the cast quality and casting parameter measurements can be repeated after a period of time has passed to allow the changes to take effect in the quality of the cast exiting the casting region. This process can be repeated numerous times during the casting operation for controlling the caster and to obtain a desired cast quality. In this manner, the cast quality and temperature measurements can be used in closed-loop control of the caster.
FIGS. 1 and 2 are illustrative of known cooling systems for continuous casters, in particular, block casters. FIG. 1 is a graphical representation of the surface temperature of a chilling block in a known block caster as a function of time as the block travels through one casting cycle. FIG. 2 is a graphical representation of the heat extraction of a chilling block in a known block caster as the block travels through one casting cycle.
In FIG. 1, a chilling block exits the cooling system of the caster and contacts molten metal at point 10, causing the block surface temperature to rise sharply until it reaches an apex at point 20. The temperature at the surface of the block slowly decreases from the apex at point 20 as the block travels through the casting region extracting heat from the molten metal and the molten metal becomes solidified. The block then leaves the casting region at point 25 and block temperature slowly drops until the block enters a cooling region at point 30, where it is contacted with cooling fluid, transferring heat from the block to the cooling fluid, causing a rapid drop in the surface temperature of the block. Between point 30 and the point where the block exits the cooling region at point 40, the formation of several temperature spikes 50 indicates that the block surface temperature rapidly rises and falls as the block travels between rows of nozzles spraying cooling fluid on the block in the cooling region. Temperature spikes 50 indicate that thermal shocking and stressing through uneven cooling is occurring in the block as the block moves toward equilibrium while moving through uncooled gaps between rows of nozzles in the cooling system.
In FIG. 2, the heat extraction curve for a chilling block undergoing thermal shocking through one casting cycle roughly corresponds to the temperature profile of the block surface as the block travels through one casting cycle. The crosshatched area Q S under the curve between points 60 and 70 indicates the total heat extracted (in Joules) from the molten metal by the block in the casting region. The crosshatched area Q B above the curve between points 70 and 80 indicates the total heat extracted by the cooling fluid from the block in the cooling region. Areas Q S and Q B are substantially equivalent indicating no total heat buildup in the caster during steady-state cooling. As used herein, the phrase "substantially equivalent" refers to approximate equivalency in value. For example, in a block caster, areas Q S and Q B are substantially equivalent, however, they are typically not exactly equivalent because of heat losses, such as those that occur as a result of the transfer of heat from the chilling blocks to the other parts of the caster. The spikes 90 in area Q B are indicative of thermal shocking experienced by the block while travelling through uncooled gaps between nozzles in the cooling system.
FIGS. 3 and 4 are illustrative of the reduced thermal shocking and improved control over thermal loading obtained by use of one embodiment of the method and apparatus of the present invention in a continuous block caster. FIG. 3 is a graphical representation of the surface temperature of a chilling block as the block travels through one casting cycle using one embodiment of the method and apparatus of the present invention. FIG. 4 is a graphical representation of the heat extraction achieved by a chilling block as the block travels through one casting cycle using one embodiment of the method and apparatus of the present invention.
FIG. 3 illustrates reduced thermal shocking of a block using one embodiment of the cooling system of the present invention. The present invention provides multi-stage cooling over a greater range of the casting cycle, between points 30' and 40'. The gradual cooling provided by one embodiment of the method and apparatus of the present invention between points 30' and 40' substantially eliminates thermal spikes caused by temperature fluctuations at the surface of the block in the cooling system. Thus, the thermal spikes 50 in FIG. 1 generated by known cooling systems no longer appear. Also, the control of the rate of heat transfer between the block and the molten metal and the block and the cooling fluid has reduced the rapidity in the temperature fluctuations of the block surface as evidenced by the smooth curve between points 30' and 40'.
FIG. 4 is an illustration of the effects one embodiment of the method and apparatus of the present invention can have on heat extraction. Because mold cooling in the present invention can be achieved more gradually than in known systems, heat can be extracted over a larger portion of the casting cycle. The total heat extracted (in Joules) by the cooling apparatus of the present invention Q' B is observed to be substantially equivalent to the total amount of heat extracted by the mold during casting Q' S . This relationship indicates that steady-state cooling can occur using the method and apparatus of the present invention.
The apparatus and interaction of the components of the apparatus of the present invention can be more readily understood by reference to FIG. 5. FIG. 5 is an illustration of one embodiment of the cooling and cleaning apparatus of the present invention in a continuous block caster having two horizontal casting loops, such as can be used in the production of aluminum strip. In continuous block caster 100, a plurality of cooling stages 105, 110, 115, 120, and 125 are used for cooling the blocks. As the mold blocks travel through the casting loop 130, they encounter the cooling stages. Each successive cooling stage increases the amount of cooling fluid, in this case water, that contacts the blocks. Thus, cooling stage 110 contacts the blocks with a greater volume of water than cooling stage 105, and cooling stage 115 contacts the blocks with a greater volume of water than cooling stage 110, and so forth. Cooling stage 105 also includes a cleaning stage, comprised of a dry brushing apparatus and a vacuum for removing the used Edelweiss blackwash coating and any other unwanted matter from the casting surfaces of the blocks. Cooling stage 125 includes a high pressure water spray for removing any leftover debris on the blocks. The Edelweiss blackwash coating apparatus 140, for example an atomizing sprayer, reapplies a fresh coating of Edelweiss blackwash each time a block is cleaned as it travels through the casting loop 130. As the blocks continue to travel through the casting loop 130, they contact molten metal 145 being poured from the tundish 150. The molten metal is formed into a strip 160 as the blocks are forced together to form a flat plane, moving mold in the casting region 155.
The system controller 165 receives data from a plurality of fixed position 170 temperature sensors which are electronically linked to controller 165. The system controller also receives data from temperature sensors 175 embedded in the blocks. The data obtained by the embedded temperature sensors 175 are preferably transmitted to the controller through a telemetry unit 180 which is electronically linked to controller 165. Quality of the cast is also measured optically by cameras 185 as the cast strip 160 exits the casting region 155. The condition of the casting surfaces of the chilling blocks can be examined using cameras 186. This information is transmitted to controller 165. After receipt of data from the various sensors 170, 175, 185 and 186, the controller 165 is capable of manipulating the controls of the caster to modify the quality of the strip 160 being cast. For example, the controller 165 is capable of manipulating, among other things, cooling of the blocks in the x-direction and y-direction by controlling the cooling and cleaning stages 105, 110, 115, 120, 125, the caster drive systems 190, the pouring of the metal from the tundish 150, and the block coating application 140. The controller 165 can be capable of substantially immediate response to the strip quality measurements in manipulating the controls of the caster, such as in the case of closed-loop control of the caster.
The placement of embedded temperature sensors in one embodiment of the apparatus of the present invention can be more readily understood by reference to FIG. 6. FIG. 6 is an illustration of a cross section of a block assembly, consisting of a chilling block 300 and a block holding plate 310, and a support beam 320, such as are used in a block chain of a continuous block caster. The imbedded temperature sensors 330 can be distributed throughout the block assembly and the support beam as shown in the y-direction 340 and the z-direction 350. A telemetry device 360 can be included in a flange on the support beam for transmitting the temperature measurement data obtained from the imbedded temperature sensors to a controller or the like. The number and placement of the temperature sensors can be modified depending upon the requirements necessary for monitoring and controlling the cooling process.
The methods and interaction of steps in the methods of the present invention can be more readily understood by reference to FIGS. 7a through 7c. FIGS. 7a through 7c are a block diagram of one embodiment of the methods of the present invention for controlling mold cooling and cleaning in a continuous block caster. Desired casting parameters and initial caster control settings, such as caster speed and the flowrate of metal being poured from the tundish, can be input 400 by an operator into the caster controller. The caster can then be started 410 and will begin to produce a continuous casting using the initial caster settings. Simultaneously, casting parameters, such as casting temperatures and cast quality, can be measured for use in controlling the casting operation.
Optical inspection of the cast slab 420 and block 430 surfaces can be performed to determine the slab surface quality 440 and block surface condition 450. From the cast slab quality and block surface condition measurements, determinations 445 and 455 can be made whether the cast slab is within an acceptable range of the desired cast quality. If the cast quality is acceptable 447, 457, then the caster controls will typically remain unchanged unless other measured casting parameters require that a change be made, or if experimentation with caster controls is desired to obtain a more preferable cast quality. If either the cast quality or the mold surface condition is unacceptable 449, 459, determinations must be made whether the molten metal is castable 460, 465. If the cast is determined to be uncastable 470, 475, for example, the cast fails upon leaving the casting region, a warning signal can be displayed to the caster operator 480, 485, and the casting operation can be terminated. If either the cast quality or the mold surface condition is unacceptable 449, 459, however the cast is determined to be castable 490, 495, the casting parameters, such as the rate of heat transfer can be altered. For example, the heat extraction rate can be altered as shown by changing interface conditions, such as the application of a surface coating to the chilling blocks 500. As another example, high pressure cleaning fluid spray in the cleaning system can be activated to reduce the amount of unwanted debris on the block surfaces (not shown).
Concurrently with optical measurements 420 and 430, block temperatures 510, cast slab surface temperatures 520, and melt temperature in the tundish 530, can be measured for one casting cycle. If the cast quality is acceptable, i.e. within a range of the desired cast quality, the various measured temperatures can be used to track and calculate trends or monitor changes in the cast, such as those which occur with a change in the caster controls. The phrase "mean temperature", as used herein, refers to the mean temperature determined for each casting cycle. For example, the mean temperature of a block for a given position inside the block can be computed 540, the mean temperature of the melt can be computed 550, the slope of the plotted curve of measured temperatures for a given position inside a block versus time 560, and the slope of the plotted curve of measured temperatures for a given position on the slab surface versus position in the y-direction 570, can be calculated.
The computed values for the mean temperature of a block 540, and the slope of the plotted curve (or heat balance obtained therefrom) 560 can be analyzed and compared to data obtained from previous casting cycles 575, 577. If such analyses 575, 577, reveals no undesirable trends or changes 580, 585, for example, no over-cooling or over-heating of the mold, then the slope of the plotted curve of measured temperatures for a given position inside a block versus position in the z-direction 590 can be calculated. If such analysis 600 reveals no undesirable trends or changes in the data received (or heat balance obtained therefrom) 610, the caster controls will typically remain unchanged unless other measured casting parameters require a change be made, or if experimentation with caster controls is desired to obtain a more preferable cast quality. If through analysis 600, the slope of the plotted curve (or heat balance obtained therefrom) 590 exhibits an undesirable trend 615, the casting parameters, such as the rate of heat transfer can be altered. For example, the heat extraction rate can be altered as shown by changing interface conditions, such as the application of a surface coating to the chilling blocks 620.
If through analysis 575, the slope of the plotted curve (or heat balance obtained therefrom) 560 exhibits an undesirable trend 625, the casting parameters, such as the cooling of the block in the x-direction can be modified. For example, the flowrate of cooling fluid per nozzle, or row of nozzles in the x-direction in one or more cooling stages can be altered 630.
The computed values for the slope of the plotted curve (or heat balance obtained therefrom) 570 can be analyzed and compared to data obtained from previous casting cycles 635. If such analysis 635 reveals no undesirable trends or changes in the data received (or heat balance obtained therefrom) 640, the caster controls will typically remain unchanged unless other measured casting parameters require a change be made, or if experimentation with caster controls is desired to obtain a more preferable cast quality. If through analysis 635, the slope of the plotted curve (or heat balance obtained therefrom) 570 exhibits an undesirable trend 670, the casting parameters, such as the cooling of the block in the y-direction in one or more cooling stages can be modified. For example, the flowrate of cooling fluid per nozzle, or column of nozzles in the y-direction in one or more cooling stages can be altered 675.
The computed values for the mean melt temperature 550 can be analyzed and compared to data obtained from previous casting cycles 680. If such analysis 680 reveals no undesirable trends or changes in the data received 685, the caster controls will typically remain unchanged unless other measured casting parameters require a change be made, or if experimentation with caster controls is desired to obtain a more preferable cast quality. If through analysis 680, the mean melt temperature 650 exhibits an undesirable trend 690, for example, large, rapid temperature fluctuations, and if through analysis 577, mean block temperature 540 exhibits an undesirable trend 695, for example, over-heating of the mold, the casting parameters, such as the cooling of the block can be modified. For example, the total flowrate of cooling fluid in one or more cooling stages can be altered 700.
After the changes in the casting operation have been conducted, new cast quality and temperature measurements can be taken after a period of time to allow the changes in the caster controls to take effect in the slab quality 710. If additional changes are needed, the casting parameters can be repeatedly altered in response to the measured casting parameters to obtain the desired cast quality 720.
While various embodiments of the present invention have been described in detail, it is apparent that further modifications and adaptations of the invention will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention.
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The method includes the start up parameters are inputted into a device which controls the caster. Molten metal is cast in a moving mold and cooled by extracting heat from the moving mold, which in turn extracts heat from the molten metal. Casting parameters are obtained for a casting cycle and sent to the device which controls the cooling of the metal being cast. Data from one cycle is compared to data from a previous cycle and the cooling of the metal being cast is automatically controlled in response to the comparison of data.
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The present invention relates generally to medical and surgical devices and methods, and in particular, relates to electrodes which are designed to be inserted through the circulatory system and into a patient's heart for purposes of permitting an artificial electronic stimuli to pace the patient's heart.
The term "pacemaker" generally applies to a device from a family of electronic products which is electrically connected through an electrode for providing electronic pacing impulses to a patient's heart.
One type of pacemaker, referred to as a permanent pacemaker, is packaged in a small, portable container and is usually implanted under the patient's skin in a major surgical technique. Pacemaker implants are carried out in an operating room or similar facility equipped with a fluoroscope, which permits the attending physician to precisely position the extremity of the permanent pacemaker electrode in a desired location in the heart.
Another type of pacemaker provides temporary pacing stimuli to the patient, and employs an electrode which is designed to be inserted by a physician in a rapid manner while the patient is in an emergency room, intensive care unit, catheter laboratory or similar facility.
Generally, a fluoroscopic unit of some type is used during insertion of a temporary pacing electrode, but occasionally in emergency situations, "blind insertion" has been attempted, but with limited success.
It is well known that the heart may be effectively "paced" by an electronic stimulus located within the right atrium. However, it is very difficult to locate the extremity of an electrode in an appropriate location which is stable in the right atrium, even with the benefit of fluoroscopy. Without the benefit of fluoroscopy (as during the blind insertion of a temporary pacing electrode under the emergency circumstances described above), it has been heretofore unknown to insert a temporary pacing electrode in the right atrium. Because of the inability to effectively locate an electrode within the atrium in a stable manner, most pacing electrodes (both temporary and permanent) are inserted in the right ventricle, which offers stable positioning.
In my U.S. Pat. No. 4,166,469, issued Sept. 4, 1979, I disclose apparatus and a related method for the rapid and atraumatic insertion of pacemaker electrodes through the subclavian vein.
SUMMARY OF THE INVENTION
The present invention contemplates a method and related apparatus for rapidly accurately inserting pacing electrodes, particularly temporary pacing electrodes, into the right atrium. The invention is also based, in part, on the recognition that the insertion through the right subclavian vein of a curved, or "J" electrode into the right atrium will always engage the right atrium in a stable manner when the electrode is oriented and manipulated in a predetermined direction and manner.
More particularly, the electrode of the present invention contemplates a pacing electrode including a flexible conductor having an outer, electrically insulating sheath about the conductor, the conductor and the sheath forming a flexible curve at one end with the conductor having an exposed terminal along the flexible curved end, the terminal adapted for making electrical endocardial contact. Means are further provided along the sheath for indicating the orientation of the curve after the curved end has been inserted into the heart.
In a preferred embodiment of the electrode in accordance with the present invention, the orientation indicating means is dimensioned along the sheath at a position outside the patient's body when the curved end has been inserted through the circulatory system and into the heart. Suitably, the orientation indicating means comprises a wing extending laterally from the sheath, the lateral direction of the wing indicating the orientation of the curved end. One side of the wing is provided with means for indicating which side of the wing should be facing away from the patient. The desired orientation will be obtained in accordance with the present invention when the wing lies flat against the patient's skin, with the "up" indicating means properly positioned.
In accordance with another aspect of the present invention, the electrode includes means for indicating the distance along the sheath from the curved end, permitting the attending physician to first insert the straightened curved end through the circulatory system, manipulating the straightened electrode into the right atrial cavity and permitting the curved end to reform with its extremity pointed toward the right atrial appendage, and thereafter engaging the extremity of the curved end against the right atrial wall in a stable manner by withdrawing the electrode from the circulatory system a distance as determined by reference to the distance indicating means along the sheath. The distance indicating means may be a series of gradations along the outer periphery of the sheath.
DESCRIPTION OF THE DRAWINGS
FIG. 1(a) is a front view of the human anatomy, particularly illustrating the human heart with a portion cut away to show the inside of the right atrium and a portion of the right ventricle.
FIG. 1(b) is a side view illustrating a portion of the human anatomy, and specifically illustrating the curvature of the subclavian vein as it enters and connects with the superior vena cava.
FIG. 2(a) is a front view, partially cut away, illustrating an electrode in accordance with the present invention.
FIG. 2(b) is a front sectional view of the electrode of FIG. 2(a), along the line 2(b)--2(b).
FIG. 2(c) is an enlarged illustration of the end section of the view of FIG. 2(b).
FIG. 3 is a front view of the human heart, the subclavian and cephalic veins and their connection to the superior vena cava, with portions of the superior vena cava and the heart cut away to illustrate the manner in which the electrode of the present invention is utilized.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will now be described with reference to the drawings. While one particular structural arrangement of the electrode in accordance with the present invention is shown in the drawing and described with reference thereto, it will be understood by those skilled in the art from the detailed description set forth below that various modifications may be made in the design of that electrode without departing from the spirit and scope of the present invention.
With particular reference to FIGS. 1(a) and (b), there is illustrated a human body 10, the right subclavian vein 12, the cephalic vein 14 and the superior vena cava 16. The drawing of FIG. 1 is fanciful in nature, it being understood that the drawing is not to scale, but serves only to illustrate the functional relationships of the heart and associated circulatory system.
Element 18 refers to the heart, which includes the right atrium 20, the right ventricle 24, and the inferior vena cava 22. The wall between the right atrium 20 and the right ventricle 24 is cut away in the area where the tricuspid valve would normally be located for purposes of permitting illustration of the right ventricle. As is known, blood from the arms, head, and body flow into the right atrium 20 via the superior vena cava 16 from, among others, the subclavian and cephalic veins 12 and 14. Blood from the trunk and legs enters the right atrium 20 via the inferior vena cava 22.
As is also known, there is a portion of the right atrium known as the right atrial appendage, identified as element 26 in FIG. 1a. The right atrial appendage 26 is a small ear-like appendage forming a pocket located anteriorly and superiorly on the right atrial wall, the inner surface of which is particularly susceptible to pacing.
Noting FIG. 1(b), it is seen that the curvature of the subclavian vein to the connection with the superior vana cava 16 is not flat, as it appears in FIG. 1(a), but rather is curved toward the rear of the patient's body, i.e. in the direction toward the spinal column, coming from the forward surface of the body 10.
Reference is now made to FIGS. 2(a), (b) and (c), which disclose a temporary pacemaker electrode in accordance with the present invention.
The electrode, referred to generally by the reference numeral 30, includes a flexible, electrically insulated sheath 32 with a pair of concentric conductors 34, 36 surrounding a central lumen 38 which may, though not necessarily, extend through the electrode 30 to the distal end 39. Each of the conductors 34, 36 are insulated by a layer of insulating material (not numbered--see FIG. 2(c)).
Each of the conductors 34, 36 are exposed at the surface of the outer insulating sheath 32, in order to permit electrical contact in the heart when the electrode 30 is in place. By way of example, conductor 34 may have a surface terminal 42 and inner concentric conductor 36 may have a surface terminal 48 at the distal extremity 39. Typically, the outer conductor 34 will serve to shield the inner conductor 36, and the inner conductor will therefore be relied upon to provide pacing signals at the distal extremity 39 of the electrode 30. In accordance with a preferred embodiment of the present invention, the terminal 48 consists of a spherical conductor connected electrically with the inner conductor 36.
Referring again to FIG. 2(a), the proximal extremity of the electrode 30 includes a hub 52 having an opening 54 which communicates with the central lumen 38. Each of the concentric conductors 34, 36 include external portions which likewise exit the electrode 30 at the proximal end 50, typically in the manner shown in FIG. 2(a). As is well known, the proximal extremities of each conductor 34, 36 may be connected to a temporary pacemaker (not shown).
As is shown on the right-hand side of FIG. 2(a), the electrode 30 is provided with a somewhat gentle curve 44 between the terminal 42 and the distal extremity 39 which permits the conductor terminal 48 at the distal extremity 39 to be pointed in a direction approximately 180° + from the direction of the electrode 30, and in a plane substantially parallel with the plane of the electrode; that is to say, when the main body of the electrode 30 is lying on a flat surface, the curved portion 44 and the distal extremity 39 are likewise lying in the plane of the same flat surface. The insulative sheath 32, including the insulative materials between the conductive electrodes 34, 36 are of a material which has an elastic memory so that when the curved portion of the distal extremity 39 of the electrode 30 is straightened in the manner hereinafter described, the curved portion at the distal extremity 39 will thereafter resume its curved configuration. A number of conventional silastic and other non-toxic plastic materials are suitable for this purpose.
Straightening of the curve 44 of the electrode 30 may be accomplished by simple manipulation with the hands, or with a stylet having an outer diameter sufficiently small to permit it to pass through the opening 54, down the central lumen 38 to straighten the curved end and hold the entire electrode, including the distal extremity straight. The stylet must be sufficiently flexible to permit the electrode to pass through the subclavian vein 12, the superior vena cava 16 and into the right atrium 20.
In accordance with the present invention, the electrode 30 is provided with means for indicating the relative position of the curved distal extremity 39 with respect to the axial direction of the electrode 30 and the plane in which the electrode and the curved extremity lies. In the embodiment shown in FIG. 2(a), the indicating means in this regard comprises a pair of flat, relatively flexible plastic wings 59, 60 which extend laterally from the outer insulated sheath 32, joined by a sleeve 61. As is shown in FIG. 2(a), the indicating wings 59 and 60 extend generally perpendicular to the plane of the curve 44, the distal extremity 39 and the main body of the electrode 30. As shown in FIG. 2(a) and (b), the wings 59, 60 are curved slightly downward and include the notation "UP" on the upper side intended to be away from the patient's body, as described further below.
The electrode 30 further includes means for indicating the distance along the insulating sheath 32 from the curve in the distal extremity 39. In the embodiment of FIG. 2(a), this distance indicating means comprises a series of gradations along the insulating sheath 32 forward of the indicating wings 59, 60 in the direction of the curve of the extremity 39. Typically, the gradations may include wide gradations 62 and thin gradations 64, each wide gradation indicating a 10 cm. segment and each thin gradation indicating a 5 cm. segment; thus, an individual marking of two wide gradations and one thin gradation would indicate a 25 cm. distance from the curved end.
The manner in which the electrode of the present invention is employed for insertion through the right subclavian vein and into the right atrium without the use of fluoroscopy will now be described with reference to FIG. 3.
Before beginning the technique of inserting the electrode 30 in the manner hereinafter described, the patient is properly prepared and normal sterilization techniques are observed.
Initially, a puncture is made through the patient's skin in the area adjacent the clavicle so as to pass a small, thin-walled 18 gauge needle into the right subclavian vein 12, to thereafter permit the introduction of a removable introducer in the manner which is clearly described in my U.S. Pat. No. 4,166,469. Because the technique for inserting a removable introducer sleeve into the right subclavian vein is clearly described in the specification of that patent, it is incorporated here by reference.
Once that sleeve is properly inserted, the curve 44 of the electrode 30 is straightened. The electrode 30 is then inserted down a removable introducer sleeve (not shown in FIG. 3, but see sleeve 56 in FIG. 11 of my aforementioned U.S. Pat. No. 4,166,469). Once the straightened distal extremity 39 of the electrode is inserted down the introducer sleeve into the subclavian vein 12, it is then manipulated through the superior vena cava 16 and into the right atrium 20. The removable introducer sleeve is then removed by peeling it away, allowing the wings 59, 60 to be positioned close to the entrance site into the subclavian vein 12.
At this point in the technique, the electrode 30 has been inserted as desired so that the straightened distal extremity 39 is positioned in the right atrium 20. It will be understood that the insertion technique thus far described leaves the indicating wings 59 and 60 exteriorly of the patient's skin. As a next step, the attending physician ensures that the indicating wings 59 and 60 are lying substantially parallel to the plane of the patient's skin, and with the words "UP" facing the physician. If a stylet is being used, the stylet is removed. In either event, the curve 44 resumes its normal, curved configuration, as is shown by dotted lines on the right side of FIG. 3.
If the physician has inserted the electrode a sufficient distance into the subclavian vein 12 (and down the superior vena cava 16 and into the right atrium 20), as is determined by reference to the indicating marks 62, 64 along the outer sheath 32, and if the indicating wings 59 and 60 are positioned in the manner described above, then the curved distal extremity 39 will assume a direction in which the terminal electrode 48 is pointed directly upward toward the right atrial appendage 26. This is because of the unique relationship of the curvature from the right subclavian vein 12, running down the superior vena cava 16 and into the right atrium 20, as is clearly shown in FIG. 1(b). As was noted previously, the subclavian vein 12 actually curves slightly backward toward the spinal column as it communicates with the superior vena cava 16, the superior vena cava communicating with the right atrium 20 at the rear of the heart 18. Thus, the indicating wings 59 and 60 and the curvature of the curve 44 are oriented such that when the indicating wings 59 and 60 are positioned substantially parallel to the patient's skin and with the "UP" side facing the physician, then the curve 44 at the distal extremity 39 is formed so that the conductive terminal 48 is pointed in the desired manner in the pocket under the right atrial appendage 26.
Next, the attending physician then pulls the electrode 30 slightly outward away from the puncture wound in the skin and away from the subclavian vein 12, as is shown by the arrows 68 in FIG. 3. The electrode 30 may be withdrawn in this manner a distance of between 1 to 7 centimeters, as determined by reference to the gradations 62, 64 so as to ensure that the conductive terminal 48 engages the surface underneath the right atrial appendage 26. Because of the spherical configuration of the terminal 48, that terminal makes a broad electrical contact with the wall of the right atrium 20 in the pocket of the appendage 26, but without damage to the wall. The terminal 48 stays in the desired location because of the tension at the curve 44, despite continual movement of the atrial wall.
It will be appreciated that the manipulative steps described above can take place without the benefit of fluoroscopy, thus permitting a temporary electrode to be placed easily and quickly into the right atrium 20 for purposes of obtaining the benefits of physiological atrial pacing under emergency or temporary conditions.
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A pacing electrode for rapid endocardial insertion for pacing from the right atrium of a patient and for interconnection with a pacemaker includes a flexible conductor having an outer, electrically insulating sheath about the conductor with a flexible curve at one end of the conductor and an exposed terminal along the flexible curved end. The terminal is adapted for making electrical contact with an inner heart surface, preferably within the right atrium. The curved end of the electrode is straightened during insertion through the circulatory system, and thereafter permitted to resume its curved configuration after entering the heart. A wing extends laterally from the sheath at a position outside the patient's body after the curved end has been inserted into the heart. An established relationship between the lateral direction of the wing and the curved end allows the physician to control the orientation of the curved end after insertion to permit the positioning of the electrode in a stable manner within the right atrium, whereby physiological atrial pacing may be achieved.
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